OPERATING INSTRUCTIONS PRODUCT LINE EcoPower B6

Transcription

1 OPERATING INSTRUCTIONS PRODUCT LINE EcoPower B6 EP6GBV Read before using the injection moulding machine and keep nearby for reference.

2 TECHNOLOGY working for you. Wittmann Battenfeld GmbH Wr.Neustädter Straße Kottingbrunn Österreich Tel. +43 (0) Fax +43 (0) DIN EN ISO 9001 Subject to technical changes without prior notice. We shall not accept any liability for damage caused by printing errors.

3 Operating Instructions Production line EcoPower Machine model 110 / 350 Control system type UNILOG B6 Machine number Year of manufacture 2010 Number of instruction manual EP6GBV00_0510 Date of issue

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5 Chapter 1...Preface Chapter 2... Safety Chapter 3... Technical data Chapter 4... Transport / Installation Chapter 5... Mould mounting Chapter 6... Structure and function Chapter 7... Start-up Chapter 8... Maintenance Chapter 9... Spares / Plans Chapter 10...Special descriptions Chapter Contact Contact

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7 Table of Contents 1...Preface Introduction Area of Applicability Explanation of symbols Copyright Transfer Certifi cate Certifi cate of Conformity 2...Safety Safety regulations General information Installation Operation and maintenance Safety instructions affecting personnel Safety regulations Hydraulics / pneumatics Safety regulations for the Modular Airmould System Safety regulations for moulding compounds Safety regulations for electrics Safety regulations for changing nozzle, screw and barrel Safety instructions Environment Table for risk assessment 3... Technical data General Hydraulic unit Electrical system Water system Pump capacity UNIFEED material feed unit (optional) Injection unit Clamping unit Mould dimensions Conversion table for injection weights Weights of screws and screw barrels Tightening torques of screws Tightening torques of the fi xing screws for the screw barrel head Servo motors with flange cooling (optional) Design and function Flow rate Cooling water quality Cooling water system settings Cleaning of the cooling channels Feed zone Mould mounting dimensions Foundation and installation plan EP6GBI2A EP6DEI2A 0510WT Index - 1

8 Table of Contents 4... Transport - Installation General Storage Unloading Installation layout plan Machine transport Machine installation Transport equipment and tackle Removal of preservation agent Alignment of machine Hydraulic system Filling Commissioning of hydraulic pump Bleeding system Core puller (optional) Water system Water quality Cooling water connection Oil cooling system (optional) Heating/cooling unit Pneumatic system Compressed air connection UNIFEED material feed unit Electrical equipment 5... Mould mounting Preparation Mould mounting Quick-action mould mounting system Magnetic quick-action mould mounting system Interfaces Checking the safety devices Test run and interlock test 6... Design and function Clamping unit Technical description Lubrication of toggle system Central lubrication pump Turn-out device Mechanical closing guard Injection unit Technical description Centring of nozzle Nozzle change Basic conditions for nozzle change Changing open nozzle Changing Herzog type SHP needle shut-off nozzle spring-controlled Changing Fuchslocher needle shut-off valve Changing Herzog type HP needle shut-off nozzle...(pneumatically or hydraulically operated) with integrated control cylinder Index - 2 EP6GBI2A EP6DEI2A 0510WT

9 Table of Contents Changing Herzog type BHP bolt shut-off nozzle (pneumatically controlled) with integrated control cylinder Changing Herzog type HP needle shut-off nozzle (pneumatically or hydraulically operated) Changing Fuchsloser needle shut-off nozzle (pneumatically or hydraulically operated) ENG pneumatic needle shut-off nozzle with integrated control cylinder Dismantling the screw barrel / screw Dismantling screw Dismantling the screw barrel Cleaning the screw barrel (change of injection material) Removal with high-grade polyethylene Material removal with cleaning granules Cleaning the screw barrel Storage Hydraulic system General Pump unit Hydraulic tank Return fi lter Oil cooler (optional) Indicating and control device Pressure settings Speed settings Hydraulic core puller Pneumatic system UNIFEED material feed unit Pneumatic core puller Airmould UNILOG B6 control General information Control panel Explanation of the picture Saving / Printing Control components 7... Operation General information Initial start-up Starting the machine after EMERGENCY STOP Checking the nitrogen pressure Test run without material Filling the material hopper Test run with material Operation Shutting down the machine Extended shutdown Shut down procedure Dismantling the mould Further measures for shutting down Emptying the hydraulic system Emptying the cooling water supply Evacuating the compressed air system Other measures Disconnecting the electric system Measures after an extended shutdown Changing the place of installation Disposal EP6GBI2A EP6DEI2A 0510WT Index - 3

10 Table of Contents 8... Maintenance General Transport, storage and disposal of lubricants Disposal of electrical and electronic components Hydraulic fl uid and lubricant table Maintenance schedule Hydraulic system Oil change Bleeding the system Checking the oil level Return fi lter Changing the fi lter cartridge Breather filter Leakage Oil cooler (optional) Hose lines Service life Inspection criteria Hydraulic accessories Water system Water quality Closed cooling water circuit Hydraulic oil temperature Oil cooler Cooling water fl ow controller Electrical system Filter pads Buffer battery Pneumatic system UNIFEED material feed unit Air purifi er unit Filter cartridge Mechanical closing guard 9...Spares / Plans Special descriptions Contact... Customer Service Index - 4 EP6GBI2A EP6DEI2A 0510WT

11 Preface 1 Preface 1.1 Introduction This machine documentation is written with the intention that it should be read, understood and followed by all those who will be responsible for this Battenfeld injection moulding machine (referered to as machine hereafter). The complete documentation should be held close to the machine and be available to operating and maintenance staff at all times. Only after reading through thoroughly, especially chapter "Safety" can problems with the machine be avoided and trouble free operation ensured. It is therefore essential that this operating manual be made available to the personnel concerned. This should take place before commissioning, because we can take no responsibility for damage and operating faults arising from ignorance of this operating manual! There are facilities for the training of your operating staff in your works or at our factory. For further information, contact the Training Department. Should you still encounter difficulties, please contact our Customer Service Department or our Local Technician or Agent (addresses are given in chapter "Customer Service") who will be pleased to help. This Operating Manual is valid only for the machine specified on the front cover. The presentation and content of this manual are subject to technical alteration, as required by continuous improvements of the machine and / or its plant components. 1.2 Area of Applicability Machines of this range have been designed as standard for the processing of thermoplastics and optionally for processing rigid PVC, thermoset plastics, elastomers and LIM (Liquid Injection Moulding - process for the injection moulding of liquid two part silicone rubbers). Any other use is regarded as improper. The manufacturer accepts no responsibility for any resulting damage; the risk is borne entirely by the operator. HC4GB0AA HC4DE0AA 017WT1 Chapter 1-1

12 Preface 1.3 Explanation of symbols The Warning symbol is to be found with all work safety instructions in this operating manual where there is a hazard to the health and safety of persons. Follow these instructions and act in these cases with extreme care. Pass on all work safety instructions to other users. In addition to the instructions given in this operating manual the general health and safety regulations must be observed. Warning and prohibition symbols may be present on the machine. They warn of particular dangers of death or injury to operating and maintanance personnel. The "Hot surface" sign indicates areas where there is a burning hazard. The user must be protected by appropriate personal protective equipment. Areas indicated by the "Pinch hazard" sign warn of possible pinching or crushing hazards. Surfaces marked with the "No step" symbol must not be stood on. CAUTION Caution marks those sections with these operating manual where there are instructions or regulations which must be observed and/or that the correct sequence of work should be followed, and / or that care must be taken to avoid damage to the machine and associated equipment. The High voltage symbol indicates in the manual those places where personnel can come into contact with electrical equipment and materials. Care must be taken to ensure that the applicable local electrical safety regulations are followed. The mandatory symbols, "Use face protection" and "Wear safety gloves", are to be found at the mould, mould nozzles of the machine. When the person having access to the mould area completely enters the machine (according to EN 201), the mandatory symbol "Wear personal protective equipment" is additionally to be found at the mould. They warn of particular dangers of death or injury to operating and maintanance personnel. The user must be protected by appropriate personal protective equipment. Chapter 1-2 HC4GB0AA HC4DE0AA 017WT1

13 Preface The symbol for environmental hazard draws attention to environmental hazards, for instance in disposal of all sorts of materials. When carrying out repair and maintenance work the locally applicable laws and decrees have to be complied with. 1.4 Copyright The copyright of this operating manual remains with Battenfeld GmbH. This operating manual is intended for assembly, operating and supervisory staff. It contains instructions and diagrams of a technical nature which may not be reproduced entirely or in part, distributed or used without authorisation for the purposes of competition or conveyed to third parties. 1.5 Transfer Certificate The transfer certificate enclosed with this operating manual is to confirm the transfer of the IMM and the completeness of the operating manual. After checking, the Transfer Certificate should be completed, signed and returned to the "Documentation" Department. 1.6 Certificate of Conformity The Certificate of Conformity is included at the end of this Section. HC4GB0AA HC4DE0AA 017WT1 Chapter 1-3

14 Preface Chapter 1-4 HC4GB0AA HC4DE0AA 017WT1

15 Safety 2 Safety 2.1 Safety regulations General information Numerous safety devices on the machine or the robot contribute to safety and accident prevention. The proprietor is responsible for the efficient operation of the safety devices. The machine has been designed and built to the currently applicable safety regulations in European Standard EN 201 and is safe to operate. Hazards may still arise from this machine if it is operated by untrained personnel or is used improperly or for an unsuitable purpose. For safety reasons the control software may not be modified. Any unauthorised modification to the software will invalidate possible claims of guarantee / warranty. The regulations on environmental hazards, safety and the prevention of accidents as well as the internal procedures are always applicable to the running of the machine. Unless otherwise contractually agreed upon with the manufacturer, the guarding has been designed according to safety regulations (EN 201) the for an operation of the machine at ground level. If the machine, without knowledge of the manufacturer, is installed in a pit or surrounded with a pedestal, the proprietor is obliged to adhere to the safety regulations according to the European Standard 201, and especially to EN 294. Unauthorised modifications and alterations which affect the safety of the machine are not allowed. Modifications and alterations which affect the safety of the machine as well as all work relating to maintenance are to be documented in an inspection record which is to be stored for at least ten years. Proper use of the machine includes observation of the instructions laid down by the manufacturer for assembly, dismantling, commissioning, operation and maintenance. Responsibilites and procedures for all work involving installation, dismantling, modification and maintenance of the machine are to be recorded in a procedure. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-1

16 Safety The machine has been designed and built according to the currently valid standard DIN EN so that hazards from noise emission when used properly and with optimised settings are reduced to the lowest possible level. Before operating the machine with a robot, the safety regulations in the "Robot" operating manual must be followed without fail. Before operating the machine with integrated peripheral equipment (e.g. material feeder) the safety regulations in the appropriate Peripheral Equipment Operating Manual(s) must be followed without fail. Connection and installation of peripheral equipment may only be carried out by authorised skilled technician. The proprietor has to make sure and verify that the operator is aware of the safety instructions and potential harzards and follows the operating manual at regular intervals. The installation of a Battenfeld mould-lifting crane may only be carried out by an authorised skilled technician. The crane may only be used for installing and removing moulds. It is forbidden to linger under the suspended load. The Safe Working Load is shown on the crane s specification plate. Even if the machine is only subject to slight modifications in terms of position it should be disconnected from any power supply. Reconnect all power supplies according to the operating manual before restarting the machine. If the machine is disposed of to a third party or firm, these operating instructions must be handed over with it. If is recommended to have written confirmation of this. Chapter 2-2 HC4GB0BA HC4DE0BA 017WT1

17 Safety Installation For installation, dismantling, modification, adaptation, and maintenance, work parts, components or the entire machine have to be secured and carefully attached to the lifting gear so as to prevent any dangers from arising. Only use appropriate lifting gear in proper working order with sufficient carrying force. Personnel or other persons must by no means stand or work under suspended loads. Loads may only be fastened, secured and transported by experienced, authorised and trained personnel. The machine may only be lifted using the lifting points described in Chapter "Transport - Installation". Before installation of the machine the safety measures detailed in DIN EN 292-2, Para must be complied with. After electrical installation or maintenance all the applicable safety measures (e.g protectiveconductor system, voltage test, insulation test) must be tested according to the European standard EN60204-Kpt20. Hazards may arise from this machine during setting if the setting is carried out by untrained personnel improperly or for an unsuitable purpose. Therefore, all setting work may be carried out by a tool setter only. Tool setters are persons who due to specialised training and experience have sufficient knowledge of material, moulds and the control of the machine and who are familiar with the relevant safety regulations, regulations for the prevention of accidents, directives and generally approved rules in technology, e.g. DIN standards. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-3

18 Safety Operation and maintenance All work is in principal to be carried out with the machine being idle. The appropriate isolation procedures must be followed. Before starting work on the machine its drive and periphery equipment must be secured against accidental reconnection, e.g. using a padlock on the main switch. Before reconnecting the machine the safety devices must always be checked for their proper function and to be documented by the proprietor. Before putting into operation after repair it must be verified that all the safety devices are in place according to regulations. Safety devices may only be removed with the machine switched off and secured against accidental reconnection. If the ejector or core pullers are operated with the safety door open, it must be ensured that there are no pinching or crushing points on the mould. Spare parts must meet or exceed the technical specification laid down by the manufacturer. The operator is responsible for ensuring that the electrical components, motors etc. do not come into contact with any liquid. Carefully clean the environment, especially connections and screw connections before servicing the plant. Cleaning materials are classed as flammable liquids, hazardous to health. The manufacturers instructions are to be followed without fail. Do not use aggressive cleaning agents. Use nonfibrous cleaning cloths. When using oils, greases or other chemical substances, follow the safety regulations applicable to this product. The proprietor is responsible for secure and proper waste disposal of process material. Screw connections which have become loose during operating and maintenance work must always be tightened as specified on the table. Check pipework for leaks, loosened screw connections, chafe marks, and damage. Remedy detected defects immediately. Chapter 2-4 HC4GB0BA HC4DE0BA 017WT1

19 Safety Safety instructions affecting personnel All persons involved with the machine on the proprietor s premises, whether for installation, dismantling, commissioning, operation, maintenance (inspection, service and repair) must first read and understand the appropriate operating instructions, especially chapter "Safety". The proprietor is advised to have this confirmed in writing. The machine may only be operated, maintained and repaired by authorised, trained personnel. Personnel must have undergone special instruction about possible hazards. Personnel to be trained, instructed or which has not yet finished the professional training may only work at the machine if supervised by authorised, trained and instructed staff. The operators must wear their hair tied back, close-fitting clothes and must not wear any jewels including rings. There is a danger of injury, e.g. when getting caught. Responsibilities for installation, dismantling, commissioning, operation, and maintenance must be clearly defined and adhered to so that no grey areas arise on the subject of responsibilities for safety. For all work involving assembly, dismantling, modifications and maintenance, the machine is to be switched off at the mains switch and must be secured against accidental switching on. (e.g. by inserting a padlock into the main switch). All energy supply lines to the machines (e.g. compressed air, pressurised fluids,...) must be switched off. When undertaking work involving installation, dismantling, modification, operation and maintenance, no flammable liquid may be allowed to come into contact with components whose high temperatures could cause a fire and explosion risk. Let the following components cool down to a safe temperature before carry out any work involving installation, dismantling, modification and maintenance: Heating elements and their guardings. Temperature control units, their fittings, flow and return lines and their mounting elements. The outside cooling of the screw barrel (option) and / or the barrel throat zone (option), operated with water or heat transfer oil, including all fittings, flow and return lines and mounting elements. The internal cooling of the screw (option), operated with water or heat transfer oil, including all fittings, flow and return lines and mounting elements. The operator must protect him / herself from burning hazards from the heating elements, temperatur control units and their covers, fittings, flow and return lines and their mounting elements, and the housings of electrical motors by wearing appropriate PPE. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-5

20 Safety The operator has a duty always to use the machine with closed safety gates and guards. No working method which compromises safety of the machine should be employed. The operator has a duty to ensure that no unauthorised person works on the machine. The operator and other personnel may only stand in front of the machine on the operator s side during operation. It is forbidden to stand on the machine or to reach into the injection unit during operation. The shut down procedures given in the operating manual are always to be followed for all work on the machine. The operator is obliged to report at once any alteration in the machine which affects safety. If necessary, the machine should be switched off at once by operating the emergency stop devices and the main switch. The operator has a duty always to operate the machine in a fault free condition. Cleanliness and tidiness of the machine are to be ensured by appropriate instruction and monitoring on the part of the proprietors. The operator is obliged to observe all safety regulations and danger signs at the machine. These signs must be complete and fully legible. If components of the machine are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for installation, dismantling, modification, operation, and maintenance. Do not use components of the machine as climbing aid. When working at greater heights, proper equipment for proctection against falling down must be worn. The operator has a duty to ensure that no foreign bodies enter the material hopper, stuffing device, or barrel throat. The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out. When using mould nozzles (Hot runner nozzle, Mouldmaster nozzles) the operator must ensure that there are no pinching or crushing points. The proprietor is obliged to attach corresponding safety labels to moulds (not included in the Battenfeld scope of delivery) which are equipped with mould nozzles. These safety labels must instruct the operator to use the appropriate personal protective equipment for all work involving installation, dismantling, modifications and maintenance of mould nozzles (Hot runner nozzle, Mouldmaster nozzles). When undertaking work involving installation, dismantling, modification, and maintenance of mould nozzles (Hot runner nozzles, Mouldmaster nozzles), the operator is obliged to wear appropriate personal protective equipment (protection for hands and face, etc.). Chapter 2-6 HC4GB0BA HC4DE0BA 017WT1

21 Safety Looking directly into the nozzle area itself is not allowed. Use appropriate aids (e.g. a suitable mirror). In any work involving operation, installation, dismantling, modification and maintenance, the following potential pinching or crushing hazards may arise: Between the safety door and safety door frame on closing the clamping unit s safety door(s). Between the purge guard and the nozzle platen on closing the purge guard. With power-operated shut-off nozzles from the movement of their closing mechanism. Between the nozzle and the nozzle platen when moving the injection unit forward with the purge guard open. In the area of the screw shaft and thrust bearing (axial bearing) when coupling the screw. Around the material outlet when swinging the material hopper in and out or sliding it backward and forwards. Machine with pedestal: When opening and closing the power-operated safety gate in the area of the safety gate drive. There is a crushing and / or shearing and / or impact hazard in the space for part ejection from: Moving parts of the mould area which can be reached through the space for part ejection. Falling mouldings. There is a cutting and shearing hazard at the edge of the filling opening of the hopper when filling in the melt. In the area of the Roto feeder head, for the internal cooling of the screw (option), there is a hazard of crushing and / or shearing between the rotating and fixed parts. For magnetic quick-action mould mounting systems (option), the following hazards in the clamping unit area arise from: Magnetic fields, which, when in immediate proximity, may influence sensitive devices such as cardiac pacemakers, hearing aids, disks, etc. The power of the magnetic modules which can uncontrollably magnetise objects (e.g. spanners). HC4GB0BA HC4DE0BA 017WT1 Chapter 2-7

22 Safety Safety regulations Hydraulics / pneumatics The machine is designed and built to the currently applicable safety requirements of European Standard EN 982:1996 and is safe in operation. Hazards can, however, arise from the hydraulic system of this machine if it is improperly used by untrained personnel or is used for purposes for which it is not designed. For this reasons all work involving installation, dismantling, modifications and maintenance may only be carried out by a skilled hydraulic and / or pneumatic technician. Hydraulic technicians are persons who due to specialised training and experience have sufficient knowledge in the field of oil hydraulics and who are familiar with the relevant safety regulations, regulations for the prevention of accidents, directives and generally approved rules in technology, e.g. DIN standards. Before opening hydraulic and / or pneumatic components and hoses, the hydraulic or pneumatic systems have to be relieved from pressure as described in this operating manual. Compressed air piping for the pneumatic system and water pipework for the cooling of the hydraulic unit have to be expertly installed and laid. Fittings, length and cross section have to meet the requirements. Hydraulic fluids (oils) escaping at high pressure can penetrate the skin and cause severe injury. A physician must be consulted at once as there is also a risk of infection. All pipework, hoses and screw connections should be checked for leaks and damage visible from outside at regular intervals. Remedy damage immediately. Hydraulic oil escaping at high pressure can cause severe injuries and fires. Hydraulic hoses and hose assemblies have to be replaced at the intervals given in the chapter "Maintenance", even if there are no defects to be detected which affect safety. Hydraulic hoses and hose assemblies must be protected from damaging external influences. The safety regulations for hydraulic hoses and hose assemblies to DIN and EN 201 are to be particularly carefully observed. Only hose assemblies with fittings that were either supplied or specified by Battenfeld should be implemented! All work involving installation,dismantling, modifications and maintenance of pressure vessels may only be carried out by personnel trained in this field. Chapter 2-8 HC4GB0BA HC4DE0BA 017WT1

23 Safety Work (repair, connection of a pressure gauge) on a machine with pressure vessels must not be carried out until the hydraulic pressure has been released; i.e. the pressure in the pressure vessels must have decayed completely. No welding or machining may be undertaken. The pressure vessels must be tested at their place of use by the technical standards organisation responsible in the proprietor s region before being put into operation. Pressure vessels may only be filled with nitrogen "N2". The use of other gases causes explosion hazards. Keep the test certificates for the pressure vessels and safety valves in a safe place. The proprietor is responsible for the proper condition, operation and monitoring of pressure vessels (e.g. regular testing). The relevant pressure vessel regulations can be purchased from the appropriate technical publishers. Addresses can be get from the local technical standards organisations. When disposing of used oil and lubricants the local laws and regulations are to be followed without fail. The proprietor is responsible for proper waste disposal. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-9

24 Safety Safety regulations for the Modular Airmould System The Modular Airmould System (option) has been designed and built to the currently applicable European Standard EN 292, Part 1 and Part 2, EN Part 1 and DIN EN 983 and is safe to operate. Hazards may still arise from the Modular Airmould System if it is operated by untrained personnel improperly or for an unsuitable purpose. For this reason, all work involving installation, dismantling, modifications and maintenance may only be carried out by personnel trained in this field. The Modular Airmould System must be relieved from pressure according to the descriptions in the operating manual for all work involving installation, dismantling, modifications and maintenance. Only those hose assemblies may be used which meet at least the requirements of DIN EN 853 (Type 2SN) whereas the outer layer must be permeable to nitrogen. The safety regulations according to DIN and EN 201 must also be followed. Only hose assemblies with fittings that were either supplied or specified by Battenfeld should be implemented. Only hose assemblies with fittings which comply with or exceed DIN 20078, Part 9 may be used. Hose assemblies must be mounted so that: Their natural position and movement are not hindered. In operation they are not subject to external stresses from tension, torsion or crushing. They are protected from external mechanical, thermal and chemical damage. Never paint hose assemblies. Hose assemblies must not be bent to a tighter bending radius than the minimum specified by the manufacturer. Torque settings of the union nut must be reached at 1 to 1 1/2 turns of the union nut. To ensure the proper serviceability of hose assemblies they must be assembled according to DIN After fitting or renewal, hose assemblies must be secured so that any hazard on bursting or blowing off is prevented. After fitting or replacing hose assemblies, the serviceability is to be checked by a trained and skilled technician. Chapter 2-10 HC4GB0BA HC4DE0BA 017WT1

25 Safety Nitrogen pipelines must meet or exceed the minimum requirements of DIN EN E "Seamless cold-drawn tubes for hydraulic and pneumatic pressure lines" and DIN EN "Hot-rolled plain steel products", material code number (St 37-4). According to the outside diameter of the pipeline, the bending radius must correspond to DIN The screw connection parts must meet the minimum requirements of DIN 2353 "Solderless pipe connections with cutting ring" (Heavy Series S). Pipe fittings must be designed to DIN Part 9. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-11

26 Safety Safety regulations for moulding compounds The machine is intended exclusively for the processing of moulding compound as stated in the chapter "General information". Any other use is considered improper and any loss damage or injury arising is the responsibility of the proprietor. The manufacturer can accept no liability. It is the operator s duty to ensure that no drawn in material or explosive air mixtures may be near the heating of the screw barrel or the internal cooling of the screw barrel (option) and the inlet area of the radial fans (option) for the outside cooling of the screw barrel. The operator has to make sure that the radial fans may only be used in a technically faultless condition and with undamaged electrics. When processing moulding compounds which give rise to harmful gases, dusts or vapours, the proprietor of the machine has a duty to provide suitable extraction for the protection of operating personnel. Some moulding compounds, if they are not properly dried, may spit material from the nozzle. Follow the moulding compound manufacturers instructions. It is the operator s duty to ensure that the heating of the shut-off nozzle will be reduced before shutting the machine down. Gases are formed if certain types of moulded compounds remain for a longer period of time in out of operation heated shut-off nozzle. These gases can escape explosively through the discharge bore of the shut-off nozzle. There is a burning hazard at operating temperature from: Barrel nozzles, mould nozzles. Plasticised moulding compound emerging from the nozzle. Wear appropriate personal protective equipment. Chapter 2-12 HC4GB0BA HC4DE0BA 017WT1

27 Safety Safety regulations for electrics The electrical equipment on the machine is designed and built to the currently valid standards DIN EN and IEC and is safe to operate. Hazards can, however, arise from the electrical system of this machine if it is improperly used by untrained personnel or is used for purposes for which it is not designed. Thus all work involving installation, dismantling, modification and maintenance may only be carried out by a qualified electrician (as defined in DIN VDE 0105 or DIN EN ). The electrical equipment may only be connected to a mains supply which corresponds in terms of current type, voltage and frequency to the specifications on the machine s electrical plate. The electrical supply lines must meet the requirements. The machine must be switched off at the main switch before all work involving installation, dismantling, modification and maintenance. Check the electrical equipment for lack of voltage, then earth it and and short it out. The mains supply and power heating terminals remain live even when the machine is switched off. The electrical equipment is to be checked at regular intervals. Defects such as loose connections or scorched cables must be immediately remedied. For reasons of safety, the operator must log off from the control unit after finishing the setting mode in order to prevent unauthorised persons from data entry. At the end of installation work, for safety reasons, the keys should be removed from all keyoperated switches and kept in a safe place. Legal requirements and regulations must be followed in all work involving installation, dismantling, modification and maintenance. Danger by current impact! At sockets with this information sign no portable hand-held electrical appliances (e.g. hand drill) may be attached. Not for hand-held electrical appliances suitably! No FI-protective circuit! GB Only attach electrical appliances according to the intended use of the sockets. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-13

28 Safety Safety regulations for changing nozzle, screw and barrel The nozzle, nozzle body, screw and screw barrel may be assembled or disassembled by trained and authorised persons only. It is absolutely necessary to meet the torque settings (according to the table) of the nozzle and the nozzle body. When installing a complete injection unit, only parts supplied or specified by Battenfeld may be used. When fitting or removing the nozzle, screw or screw barrel it is essential to activate and use the machine without the guarding on the injection unit. The proprietor therefore has a duty to ensure that the danger zone is adequately protected and that no unauthorised persons enter this zone. Before moving the injection or nozzle contact cylinders with their guarding on the injection unit removed it must be ensured that no tools or other materials are left on the machine. Whilst moving the injection piston or nozzle contact cylinder with the injection unit guarding removed, the operator must maintain a safe distance. Immediately after moving the injection or nozzle contact cylinders with their injection unit guarding removed, the machine must be switched off again and secured against accidental reconnection. If proper procedures are not followed during mounting or disassembly or when touching nozzle, screw, screw barrel, or its heating elements, there will be the risk of injury and burning hazards. Wear appropriate personal protective equipment. When fitting or removing the nozzle, screw or screw barrel, no tools may be used which could cause damage to these components. Chapter 2-14 HC4GB0BA HC4DE0BA 017WT1

29 Safety Safety instructions Environment Lubricants and hydraulic oils are environmentally hazardous products. For this reason, the local environmental laws and regulations concerning water, building, waste, transport, trade and safety at work must be observed. These areas of legislation include the fields of transportation, storage and waste disposal. Even the strictest compliance with all laws and regulations does not preclude accidents with lubricants. In such cases the appropriate authorities (Water Board, Police, Fire Brigade) must be notified immediately. The amount of lubricant discharged before notification is required varies from place to place. There is therefore a need to make contingency plans for preventive measures in the case of any incident with oil. This includes the existence of such a plan itself, that sufficient oil absorbing medium is in stock, that drains can be closed off and that tools and materials are available to prevent the spilled oil from escaping. Request safety specification sheets according to ISO (safety specification sheet for chemical products) for your products from your lubricant supplier. These cover: Chemical and physical properties. Protective measures, storage and handling. Measures to be taken in the event of accidents and fires. When disposing of electrical and electronic components, the local laws and regulations are to be observed. HC4GB0BA HC4DE0BA 017WT1 Chapter 2-15

30 Safety 2.2 Table for risk assessment Reasonably foreseeable inappropriate installation / use Case Hazard Consequence Remedies*) Use of unsuitable materials Use of unsuitable moulds; mould not installed Guardings are not available and the monitoring switches are disabled Overload of the machine; possibly fire or explosion risk, hazard to health due to the emission of hazardous substances Overload of the machine, uncertain operating conditions, escape of hot material High surface temperatures, moving parts during closing movement Only if the warnings in the operating manual are ignored Damage to machine components, shortcomings in production Burning hazard if accidentally touched or during maintenance work, crushing hazard from closing movement. Warnings and allowed material range in the operating manual Instructions in the operating manual Warnings, labels, instructions in the operating manual 4 Operating error Loss of machine function Instructions in the operating manual Reasonably foreseeable faults in installation and electrical connection 1 Case Hazard Consequence Remedies*) Electrical supply (voltage, No proper functioning Permanent machine Instructions in the frequency, cable size) damage operating manual 2 Unsuitable coolant (Water flow rate, pressure) Blockage, overheating Permanent machine damage Instructions in the operating manual HC6_001.XLS *) The given measures should only be carried out by trained operators / setters. Chapter 2-16 HC4GB0BA HC4DE0BA 017WT1

31 Technical data 3 Technical data This chapter contains all technical data required for the proper installation, commissioning and operation of the injection moulding machine. 3.1 General Machine type / control system Machine no. / year of manufacture Machine weight (gross/net) Main machine dimensions Sound level (DIN EN ISO ) see cover page see cover page see foundation and installation plan see foundation and installation plan 68 db(a) 3.2 Hydraulic unit Hydraulic oil, tank capacity Oil temperature (min./max.) Switch-on temperature for oil cooling system see foundation and installation plan min. 35 C (95 F) / max. 65 C (149 F) 45 C (113 F) 3.3 Electrical system Input power, hydraulic pump Engine voltage Frequency see foundation and installation plan see rating plate see rating plate Screw barrel temperature max. 350 C ( 662 F) (optional: 450 C, 842 F) 3.4 Water system Cooling water tank: Cooling water inlet Ø 3/4", 10 bar (145 psi) Cooling water return line Ø 3/4" EP6GB0CA EP6DE0CA 0510WT Chapter 3-1

32 Technical data 3.5 Pump capacity Machine type 40 (11) 50 (13) 60 (16) EcoPower 55/130 X EcoPower 110/130 X EcoPower 110/350 X EcoPower 180/350 X 0 EcoPower 180/750 X 0 EcoPower 240/750 X EcoPower 240/1330 X EcoPower 300/750 X EcoPower 300/1330 X X Standard 0 Amplified 3.6 UNIFEED material feed unit (optional) Feed capacity At 6 bar (87 psi) pneumatic pressure, 100 % operation and rated hose diameter 19 mm (0.75"), 4 m (13') of hose installed vertically. Feed capacity PA lb/h kg / h (562) 250 HM_1044.WMF (450) 200 (338) 150 (225) 100 (112) (33) 20 (65) 30 (98) 40 (130) 50 (163) 60 (195) Hose length m (ft) Chapter 3-2 EP6GB0CA EP6DE0CA 0510WT

33 Technical data Air consumption 1 Q at 100 % operation 2 Q at 50 kg (52.16 kg) of material / h 3 Q at 35 kg (80 lb) of material / h Air consumption Q n / min HM_1046.WMF (44) 4 (58) 5 (72) 6 (87) 7 (101) Pneumatic pressure (abs.) bar (psi) Sound level Sound level db / A 71 HM _1045.WMF (44) 4 (58) 5 (72) 6 (87) 7 (101) Pneumatic pressure (abs.) bar (psi) EP6GB0CA EP6DE0CA 0510WT Chapter 3-3

34 Technical data 3.7 Injection unit EcoPower 55 EcoPower 110 EcoPower 180 Injection unit 130 Screw diameter mm Screw travel mm Screw L/D ratio Calculated stroke volume cm³ 13, ,8 61,4 88,4 Specifi c injection pressure bar Max. screw speed min Max. plasticising fl ow (PS) 2) g/s 1,7 5 7,2 10,5 15,4 Screw torque Nm Nozzle travel / nozzle force mm/kn 250 / 40 Injection flow out of the machine cm³/s 30,8 50, ,2 141 Increased injection flow out of the machine (optional) 2) according to Battenfeld standard cm³/s 61, Injection unit Screw diameter mm Screw travel mm Screw L/D ratio Calculated stroke volume cm³ 13, ,8 61,4 88,4 85, Specifi c injection pressure bar Max. screw speed min Max. plasticising fl ow (PS) 2) g/s 1,7 5 7,2 10,5 15,4 9,3 13, ,5 Screw torque Nm Nozzle travel / nozzle force mm/kn 250 / / 40 Injection flow out of the machine cm³/s 30,8 50, , , Increased injection fl ow out of the machine (optional) 2) according to Battenfeld standard cm³/s 61, Injection unit Screw diameter mm Screw travel mm Screw L/D ratio Calculated stroke volume cm³ 85, Specifi c injection pressure bar Max. screw speed min Max. plasticising fl ow (PS) 2) g/s 9,3 13, ,5 19,5 31,1 40,5 49 Screw torque Nm Nozzle travel / nozzle force mm/kn 250 / / 40 Injection fl ow out of the machine cm³/s 98, Increased injection fl ow out of the machine (optional) 2) according to Battenfeld standard cm³/s Chapter 3-4 EP6GB0CA EP6DE0CA 0510WT

35 Technical data EcoPower 240 EcoPower 300 Injection unit Screw diameter mm Screw travel mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw speed min Max. plasticising fl ow (PS) 2) g/s 19,5 31,1 40, ,4 45, Screw torque Nm Nozzle travel / nozzle force mm/kn 350 / / 80 Injection fl ow out of the machine cm³/s Increased injection fl ow out of the machine (optional) 2) according to Battenfeld standard cm³/s Injection unit Screw diameter mm Screw travel mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw speed min Max. plasticising fl ow (PS) 2) g/s 19,5 31,1 40, ,4 45, Screw torque Nm Nozzle travel / nozzle force mm/kn 350 / / 80 Injection fl ow out of the machine cm³/s Increased injection fl ow out of the machine (optional) 2) according to Battenfeld standard cm³/s EP6GB0CA EP6DE0CA 0510WT Chapter 3-5

36 Technical data 3.8 Clamping unit EcoPower 55 Clamping unit EcoPower 55 Clamping force / locking force kn 550 Beam clearance mm x mm 370 x 320 Mould installation height mm Opening travel mm 250 Max. plate distance mm 600 Ejector stroke / ejector force mm / kn 100 / 25 Dry running time 1) s - mm 1, ) according to Euromap 6 EcoPower 110 Clamping unit EcoPower 110 Clamping force / locking force kn 1100 Beam clearance mm x mm 470 x 420 Mould installation height mm Opening travel mm 380 Max. plate distance mm 830 Ejector stroke / ejector force mm / kn 140 / 25 Dry running time 1) s - mm 1, ) according to Euromap 6 EcoPower 180 Clamping unit EcoPower 180 Clamping force / locking force kn 1800 Beam clearance mm x mm 570 x 520 Mould installation height mm Opening travel mm 480 Max. plate distance mm 1030 Ejector stroke / ejector force mm / kn 180 / 40 Dry running time 1) s - mm 1, ) according to Euromap 6 Chapter 3-6 EP6GB0CA EP6DE0CA 0510WT

37 Technical data EcoPower 240 Clamping unit EcoPower 240 Clamping force / locking force kn 2400 Beam clearance mm x mm 670 x 620 Mould installation height mm Opening travel mm 530 Max. plate distance mm 1130 Ejector stroke / ejector force mm / kn 180 / 40 Dry running time 1) s - mm 1, ) according to Euromap 6 EcoPower 300 Clamping unit EcoPower 300 Clamping force / locking force kn 3000 Beam clearance mm x mm 770 x 720 Mould installation height mm Opening travel mm 600 Max. plate distance mm 1250 Ejector stroke / ejector force mm / kn 180 / 40 Dry running time 1) s - mm 2, ) according to Euromap 6 Insulating panels, adapter board with T-groves, magnetic mould quick-clamping systems, etc. reduce the standard mould mounting height. For the applicable mould mounting dimensions, see dimension sheet at the end of this chapter. EP6GB0CA EP6DE0CA 0510WT Chapter 3-7

38 3.9 Mould dimensions Minimum mould size Technical data The design of the clamping plate and the 5-point toggles of the clamping system ensure uniform application of the clamping force with precision force distribution. These mechanisms can however only work properly, if the moulds are of a minimum size so that the mould clamping plates are not excessively defl ected. As the defl ection of the mould clamping plates affect the dimensional accuracy of the injection mouldings, the additional load on the mould and the function of the mould in connection with complicated constructions (multiple plate moulds, sliding moulds) strictly adhere to the values specifi ed here in order to prevent excessive loads on the clamping unit and the mould. The minimum mould dimensions specifi ed in the table (clamping unit) must be adhered to. Also take into account the required clamping force to minimise the load on the moulds and the energy consumption of the unit. At maximum mould weight, 2/3 of the weight must be mounted on the clamping plate. Also avoid eccentric mounting and ensure that the moulds are horizontally aligned with the split planes of the mould. Otherwise, the mould as well as the clamping unit might become deformed, which could reduce the service life of the guide and sealing elements Conversion table for injection weights The maximum injection weights (g / oz) are calculated by multiplying the calculated stroke volume (cm 3 / cu inch) with the above factors. PF and UP are factors used for duroplastic materials. Material Factor Material Factor ABS 0.88 PP + 40% talcum 0.98 CA 1.02 PP + 20% GF 0.85 CAB 0.97 PS 0.91 PA 0.91 PVC hard 1.12 PC 0.97 PVC soft 1.02 PE 0.71 SAN 0.88 PMMA 0.94 SB 0.88 POM 1.15 PP 0.73 PF 1.3 PP + 20% talcum 0.85 UP 1.6 Chapter 3-8 EP6GB0CA EP6DE0CA 0510WT

39 Technical data 3.11 Weights of screws and screw barrels Material Screw diameter Weight [mm] [inch] [kg] [lbs] 14 0, , , , , , , , , , , Weights of screw barrels including screws to be taken into account for screw and screw barrel replacements 3.12 Tightening torques of screws The tightening torques of screws that must be tightened with different torques are specified in the spare parts list. Strictly adhere to the prescribed torques. The tightening torques are based on a friction factor of 0.10 (μm total ) for untreated, galvanically cadmium-plated screws treated with Molycote. They do not apply to slightly oiled surfaces. Nominal thread size Assembly tightening torque - strength class 8.8 [Nm] [lbf ft] M4 3 2 M5 5,5 4 M6 9,5 7 M M M M M M M M M27x M M33x M M36x M M M EP6GB0CA EP6DE0CA 0510WT Chapter 3-9

40 3.13 Tightening torques of the fixing screws for the screw barrel head Technical data These tightening torques apply to the Allen head screws (1) used to secure the nozzle head (2). For details on strength class, etc, see spare parts lists. Standard model Assembly tightening torque - Nominal thread strength class 12.9 size [Nm] [lbf ft] M M M M High-temperature heating bands Assembly tightening torque - Nominal thread strength class GB size [Nm] [lbf ft] M M M M Chapter 3-10 EP6GB0CA EP6DE0CA 0510WT

41 Technical data 3.14 Servo motors with flange cooling (optional) Design and function 1 Fitting 2 Cooling channel in flange In order to operate the motors at a higher torque without causing excessive thermal stress, servo motors with flange cooling system are used for plasticizing and injection. The fl ange cooling system consists of U-shaped channels in the fl ange through which the cooling water is fed. The flange cooling system of the servo motors is fed through a separate cooling water circuit, which is controlled by the machine control system through the cooling water valve. The servo motors are cooled in series. Corrosion Take suitable measures to prevent corrosion or other damage caused by organic or inorganic substances to the water channels in the flanges. Corrosion can lead to leakage at the hose fittings, while deposits prevent proper heat dissipation and can block the channels. EP6GB0CA EP6DE0CA 0510WT Chapter 3-11

42 Technical data Galvanic corrosion Galvanic corrosion occurs when differnt types of metals are in contact with each other and are also in contact with a liquid (electrolyte). The anionic metal thereby releases ions into the liquid, which leads to corrosion. This can be prevented by avoiding direct contact between the metals. As the flange of the servo motor is made in aluminium, the hose fittings are all made in plastic. Biological corrosion Biological corrosion is caused by certain bacteria that cause oxidisation on metal surfaces. This type of corrosion can be prevented by adding antibacterial additives to the water. In addition, turbulence in the water flow significantly reduces the occurence of such bacteria or algae deposits. Deposits To prevent organic and inorganic deposits, the cooling water must be treated. In this process, certain substances must be removed or their concentration must at least be reduced to a level below a critical value. The main substances that can cause deposits are carbonates and phosphates, and, to a lesser extent, sulphates and silicates. Calcium carbonate deposits are for example caused by the carbonate hardness of the water Flow rate Max. water fl ow rate Aluminium / aluminium alloy m/s 1,8 Brass/bronze m/s 2,4 Steel m/s 6 Rubber/plastic m/s Cooling water quality Cooling water quality - guide values Cooling water temperature C < 30 Min. ph 7 Max. ph 8,5 Min. total hardness mol/ccm 0,5 Max. total hardness mol/ccm 10 Min. carbon hardness mol/ccm 1 Max. carbon hardness mol/ccm 2 Chloride ions (max.) mg/l 200 Sulphate ions (max.) mg/l 325 Nitrates and nitrites (max.) mg/l 50 Ammonia (max.) mg/l 0,5 Iron (max.) mg/l 0,2 Manganese (max.) mg/l 0,1 Chapter 3-12 EP6GB0CA EP6DE0CA 0510WT

43 Technical data Cooling water system settings The flow rate of the cooling water is controlled by the control system. The temperature is factory-set to 50 C. We recommend that you do not reduce the nominal temperature significantly, as this could result in condensation on cold surfaces. Compared with the cooling water required for the mould, the amount of cooling water needed for the flange cooling is low. The machine is equipped with three independent thermal fuses for the drives and the servo motors, which halt the machine with an error message in the event of an overload. In the event of an overload error Check whether the fl ange cooling system is switched on (nominal temperature 50 C, valve powered) Check the cooling water fl ow rate Cleaning of the cooling channels Deposits in the cooling channels of the fl ange cooling system can be fl ushed out with a suitable rinsing solution. We recommend using deconex 25 ORGANAZID produced by Borer Chemie. deconex 25 ORGANAZID is applied in a concentration of 2 to 5% in distilled water. To remove persistent deposits, increase the concentration. deconex 25 ORGANAZID is biodegradable and thus environmentally friendly. As its main ingredient is citric acid, it does not cause damage to aluminium. The product does not foam. The application temperature should be 20 C or slightly higher. At higher temperatures, the fl ushing effect is improved. The rinsing time is 3 to 5 minutes. After fl ushing with the product, rinse the system thoroughly with water. When handling deconex 25 ORGANAZID, observe the safety instructions of the manufacturer. EP6GB0CA EP6DE0CA 0510WT Chapter 3-13

44 3.15 Feed zone Technical data The feed zone is water-cooled. The temperature can be set at the screen and must be adjusted to a level that prevents melting of the plastic granules in the feed zone of the screw. The feed zone includes both plastic fittings and metal fittings Mould mounting dimensions See appendix of this chapter Foundation and installation plan See appendix of this chapter. Chapter 3-14 EP6GB0CA EP6DE0CA 0510WT

45 Transport - Installation 4 Transport - Installation 4.1 General After delivery of the injection moulding machine, inspect it without delay for damage and completeness of the delivery. Included with the machine are: Operating manual(s) Levelling elements (optional). All keys (for switch cabinet, protective guards, etc.) are attached to the main switch. We recommend having the machine assembled and installed on site by Battenfeld technicians. The manufacturer shall not be liable for damage caused by incorrect assembly or installation. The foundation and installation plan are included in chapter Technical data. This chapter also contains information regarding the machine weight and dimensions. These must be taken into account when installing the machine on site. The diagrams in the assembly and installation drawings are simplifi ed. 4.2 Storage The machine is suitably packaged for safe transport without damage. After acceptance of the delivery from the transport company, install and start the machine without delay. If the unit is to be stored for a prolonged period of time, contact our customer service department. 4.3 Unloading To ensure that the machine works without problems and to protect your warranty cover, it is important that the machine is unloaded properly! Transport and lift the machine only by the transport and loading devices provided and ensure that it is at all times in a horizontal position. Secure the lifting tackle against slipping! Use only nylon straps that of sufficient length. The use of other lifting tackle might cause damage to the boom. The load capacity of the crane and the lifting tackle must be sufficient to carry the load of the machine. For weight details, see chapter Technical data, foundation and installation plan! Strictly observe the transport plan attached to the machine! EP6GB0DA EP6DE0DA 0510WT Chapter 4-1

46 Transport - Installation Ensure that no persons are standing in the danger zone of any suspended load! The machine must be placed on a firm and level ground that is able to carry the weight of the equipment. If the machine is placed on uneven ground, it might not work properly or become damaged. If no suitable level ground is available for the installation of the machine, you must build a horizontal installation platform, following the specifi cations and instructions in the foundation and installation plan in chapter Technical data. If it is not possible to transport the machine by crane to its fi nal location of installation, place the unit with its entire base on a suitable transport vehicle and move it to the location of installation. 4.4 Installation layout plan For details regarding the installation layout and space requirements, see chapter Technical data. For maintenance, allow for a distance of 1.3 m (52") from all sides of the machine to the next fi xed structure. Chapter 4-2 EP6GB0DA EP6DE0DA 0510WT

47 Transport - Installation 4.5 Machine transport The machine is equipped with a transport monitoring system. Please handle the equipment according to the transport instructions. Improper handling might trigger the indicator. If there is no indicator installed or if the indicator has been triggered, please make a note to this fact in the transport documentation. EP6GB0DA EP6DE0DA 0510WT Chapter 4-3

48 Transport - Installation For the assembly, dismantling, relocation, adjustment or maintenance, individual components, assemblies of the complete machine must be carefully attached and secured to the lifting tackle to ensure that they pose no danger during transport. Use only lifting tackle and equipment that is suitable for the purpose, free of defects and has the necessary load capacity. Ensure that no persons are standing under suspended loads. The attachment, securing and transport of loads must be carried out by experienced authorised specialist person. Before installing the machine, refer to the safety measured in DIN EN 292, item and strictly adhere to them. If there are differences between the information in the transport plans and the descriptions and pictures below, always follow the instruction in the transport plans in chapter Technical data! EcoPower Transport by forklift truck When transporting the unit by forklift truck, lift it at the lifting points provided as specifi ed in the foundation and installation plan (see chapter Technical data ). Transport by crane and lifting tackle Lift the machine only by the two upper beams of the clamping unit located near the nozzle plate. To do this, lead the lifting tackle under the beams. Chapter 4-4 EP6GB0DA EP6DE0DA 0510WT

49 Transport - Installation Machine weight Machine weight TYPE kg lbs 55/ / / / / Machine installation The injection moulding unit must be installed in a dry room that is free of dust and protected against frost. The machine body must be fully placed on the levelling or wedge elements. Type Article Nr. EcoPower Swing elements NMS 160/M NE008 8 Adjustment of the swing elements The swing elements can be adjusted by means of the hex head screw. The height of the swing elements can thereby be adjusted within a range of 59 mm (2.32") to 80 mm (3.15"). To secure the device in the desired height, lock the screw (1) with a hexagon nut (2). Article Nr. Type Height Setting range 100NE008 NMS 160/M EP6GB0DA EP6DE0DA 0510WT Chapter 4-5

50 4.7 Transport equipment and tackle EcoPower guard Transport - Installation The transport equipment and tackle described in this section must be removed prior to commissioning and reattached each time the machine is to be transported! The guards at the clamping side are opened at the operating and rear side of the machine and secured with a rope slung around the machine frame and the handles of the guards. EcoPower front plate For transportation, the clamping unit is secured with two Allen head screws (2). They connect the front plate (1) to the machine frame (3) and must be removed before aligning the machine. Chapter 4-6 EP6GB0DA EP6DE0DA 0510WT

51 Transport - Installation 4.8 Removal of preservation agent Clean the rust protection grease from all bare metal moving parts and guides (beams, piston rods, etc.) and all uncoated and ungalvanised screws. To do this, use a cold detergent, white spirit, petroleum or a similar chemical and a cleaning cloth. The supplied small parts such as the screw tips, stop ring, etc. have been preserved by means of immersion. Remove the preservative wax layer. CAUTION Do NOT preserve the spindles or remove preservative from them! If required, these parts can be preserved by applying the prescribed operating grease. CAUTION Please note that even a single stroke performed before the preservative is removed can cause damage to the machine, as the preservative might become clogged in the guides, leading to wear! The cleaning agents listed above are hazardous and flammable substances. Observe the manufacturer instructions! Dispose of the agents and all cleaning cloths contaminated with them according to the applicable statutory waste disposal regulations! Injection unit Kolbenstangen Düsenandruckzylinder 2 Guide of hopper base 3 Guide rails of injection unit 4 Material feed block 5 Screw barrel, shaft and mount 6 Linear guides of injection drive 7 Screw lock EP6GB0DA EP6DE0DA 0510WT Chapter 4-7

52 Transport - Installation Clamping unit Mould clamping surface 2 Guide rails of clamping plate 3 Beams Guides and catchers of ejector Gears of mould height adjusting unit Toothed rack of closing guard Chapter 4-8 EP6GB0DA EP6DE0DA 0510WT

53 Transport - Installation 4.9 Alignment of machine To align the machine, you need a machine spirit level with an accuracy of 0.1 mm / m (0.004" / ) and a completely straight measuring rod. In addition, the machine must be equipped with levelling elements / wedges (optional). Place the machine spirit level (1) on the sliding rails (2) of the clamping unit, using the measuring rod (3). Align the machine in longitudinal and transverse direction to the injection moulding machines to an accuracy of 0.2 mm / m (0.008" / 3.281') by adjusting the levelling elements / wedges, if necessary. Injection unit The nozzle is centred at the factory; after transport, check its alignment and adjust it, if necessary. Fill in hydraulic oil; see section Hydraulic unit. Connect the machine to the electric power supply; see section Electrical system. Select Setup mode. Move the injection unit back until the nozzle is fl ush with the nozzle side of the mould clamping surface. Shut down the main switch and secure it against inadvertent switching on. For instructions regarding the centring of the nozzle, see chapter Design and function. EP6GB0DA EP6DE0DA 0510WT Chapter 4-9

54 Transport - Installation Chapter 4-10 EP6GB0DA EP6DE0DA 0510WT

55 Transport - Installation 4.10 Hydraulic system All work on the hydraulic system must be carried out by a specialist hydraulic technician! If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! The hydraulic system is depressurised, if the clamping plate, the nozzle and the screw are in one of their end positions. To release any residual pressure, carefully loosen (but not open) one of the hydraulic screw fi ttings. In hydraulic systems with pressure vessels (optional), wait until they have also been fully depressurised. For detailed instructions, see chapter Maintenance, section Checking of the hydraulic pressure. The main switch must be set to its OFF position and secured against inadvertent switching on Filling To gain access to the oil fi ller (1), open the safety gate at the operating side or remove the front cover. EcoPower EP6GB0EA EP6DE0EA 0510WT Chapter 4.9-1

56 Transport - Installation CAUTION Upon delivery, the hydraulic system of the machine meets the requirements of cleanliness class 17/15/12 according to ISO If the system becomes contaminated so that it does not meet this standard any longer (e.g. due to the use of an unsuitable hydraulic oil or improper filling procedures), the warranty of the system shall be voided! Hydraulic oil contaminated with water is of low quality and must not be re-used! Fill the hydraulic tank only with the hydraulic oil specifi ed in chapter Maintenance. For the required oil volume, refer to the foundation and installation plan (in chapter Technical data ). CAUTION Test the hydraulic oil for water contamination! Never switch on the machine when it is not filled with hydraulic oil. Even short runtimes can cause damage to the hydraulic system! When fi lling the system for the fi rst time, strictly adhere to the sequence of steps below: Clean the fi ller screws and caps of the transport and storage containers of the hydraulic oil. Check the quality of the hydraulic oil; for instructions, see chapter Maintenance. Filter the hydraulic oil in a mobile fi lter unit with fi lter size 3 μm ( μinch). Ensure that the main switch of the machine is in the OFF position and secured against inadvertent switching on. If necessary, remove the protective guards or covers. Clean the area around the fi ller and breather fi lter. Unscrew the plug of the fi lling and breather fi lter (ensure that the fi lter screen remains in its position). Chapter EP6GB0EA EP6DE0EA 0510WT

57 Transport - Installation Initial filling of the oil tank with Clamping side open Fill the hydraulic tank through a mobile fi lter unit with fi lter size 3 μm ( μinch) until the fl oat in the oil sight glass reaches the max. mark. The oil sight glass is located at the clamping side of the machine. Switching level 50 mm (1.97") HM_1014.PMP In this situation, do not fill in oil to the max. mark. CAUTION Before switching on the machine, allow the hydraulic oil to settle for 1 hour so that all air bubbles can escape! EP6GB0EA EP6DE0EA 0510WT Chapter 4.9-3

58 Commissioning of hydraulic pump Transport - Installation Activating the pump idling program for the pump system 1 and pump system 2 (optional equipment) UNILOG B6 Starting machine If there is air in the pump system, for example after the replacement of the pump or an oil change, this air is removed from the system by running this program. The pump program should be activated for approx. 20 minutes. Subsequently deactivate the program. During machine operation, the oil level should always be between the max. and min. mark. If the maximum filling level is exceeded, hydraulic oil escapes through the breather filter! In this case, clean the intake pipe and the filter housing and replace the filter cartridge! Reinstall the fi lling and breather fi lter on the pipe piece. If necessary, mount the protective guard or cover. Chapter EP6GB0EA EP6DE0EA 0510WT

59 Transport - Installation Bleeding system After the hydraulic tank has been fi lled, you must bleed the hydraulic system. Connect the machine to the electric power supply; see section Electrical system. Connect the machine to the cooling water system, if necessary; see section Water system. Start the hydraulic drive with the Hydraulic Start button. Press the Setup button. Open all safety gates once and close them again. Move the clamping plate, the nozzle and the screw several times back and fore across the entire stroke length. The system is properly bled, if no oil foam is visible in the hydraulic tank, all movements are performed smoothly and there are no unusual machine noises. After bleeding, check the oil level and add oil, if necessary. Only add oil of the same grade. Any leakage occurring within the fi rst few hours of operation can normally be eliminated by retightening the fi ttings Core puller (optional) See chapter Design and function. The hydraulic core pullers must be connected and commissioned by a specialist hydraulic technician! Always strictly adhere to the safety instructions in chapter Safety! EP6GB0EA EP6DE0EA 0510WT Chapter 4.9-5

60 Transport - Installation Chapter EP6GB0EA EP6DE0EA 0510WT

61 Transport - Installation 4.11 Water system CAUTION When installing the water lines, observe the corrosion properties of metal components when exposed to water as laid down in DIN 50930! Water quality If the quality of the water at your site deviates from the guide values below, please contact our technical customers service or one of our agents. For addresses, see chapter Customer service. ph: Water hardness: < 1.8 mmol / l (681 ppm / gal) Suspended particles: < 0.03 (30 ppm) Filter mesh size: < 100 μm (0.004") As regards suspended particles and water hardness, please note that the concentration of suspended particles must be lower the harder the cooling water. If the concentration of suspended particles is above 0.03 (30 ppm), install a water fi lter with a fi lter mesh size of < 100 μm (0.004") in front of the water system. We recommend adding a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel). Recommended anti-freeze agent: ethylene glycol type 420 (60 % water, 40 % ethylene glycol). This additive is suitable for temperatures down to -30 C (-22 F) and also serves as a corrosion inhibitor. Max. water fl ow rate Aluminium / aluminium alloy m/s 1,8 Brass/bronze m/s 2,4 Steel m/s 6 Rubber/plastic m/s 5 Cooling water quality - guide values Cooling water temperature C < 30 Min. ph 7 Max. ph 8,5 Min. total hardness mol/ccm 0,5 Max. total hardness mol/ccm 10 Min. carbon hardness mol/ccm 1 Max. carbon hardness mol/ccm 2 Chloride ions (max.) mg/l 200 Sulphate ions (max.) mg/l 325 Nitrates and nitrites (max.) mg/l 50 Ammonia (max.) mg/l 0,5 Iron (max.) mg/l 0,2 Manganese (max.) mg/l 0,1 EP6GB0FA EP6DE0FA 0510WT Chapter

62 Transport - Installation Cooling water connection If the cooling water system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! The cooling water devices of the machine can also be connected to a closed cooling circuit. Use clean and lime-free water, if possible. The required nominal diameters of the hoses are specifi ed in chapter Technical data. The diameters of the inlet and outlet lines must not be smaller that those of the connections on the machine. The machine is equipped with a four-circuit cooling water battery of type WITTMANN fl ow controller series 101. One of the four cooling water circuits is assigned: Cooling of feed zone Depending on the requirements of the customer, the machien can be factory-equipped with various types of cooling water batteries. The following fi gures are therefore examples only. To prevent galvanic and/or biological corrosion as well as organic and inorganic deposits, observe the following: Cooling water quality requirements Instructions by BATTENFELD for the operation of the motor fl ange and feed zone cooling (see chapter 13) Instructions of the mould manufacturer Use of material for fi ttings, hose lines and pipes that takes into account the electrochemical series The feed and outlet lines must be installed in such a way that they cannot become damaged. Ensure that the hoses do not present a tripping hazard. The cooling water inlet and outlet lines must be installed with G1" to the machine. The connections of the cooling water battery must consists of G 3/4" lines. If rigid pipes are used, you must install hose inserts for the inlet and outlet. The cooling water battery is equipped with a 3/4" hose nipple. The inlet at the cooling water battery must always be connected at the lower hose connection, while the return line is connected at the top. Chapter EP6GB0FA EP6DE0FA 0510WT

63 Transport - Installation Cooling water outlet, 3/4" connection 2 Cooling water inlet, 3/4" connection The inlets and outlets of the mould are connected at the base of the cooling water battery. The feed connections are located at the front, and the return connections at the back. In machines with controlled cooling circuits (optional), the return connections are located at the front and the feed connections at the back! The cooling water circuit can be controlled with suitable equipment installed in the feed or the return line. This means that the water circuit can be operated under pressure or without pressure. In highly restricted cooling water circuits, it is often advisable to control the return fl ow to ensure that water fl ows through all cooling water channels. The cooling water battery can be connected to a heater, if there is a need to heat up the moulds. The transparent pipe sections with scales and fl oats allow the operator to monitor the fl ow rate in each cooling water circuit. These pipe sections are easy to clean by unscrewing the screw cap at the top and cleaning the pipe with the brush. Alternatively, the pipe can be removed by pulling it out. The greater the fl ow rate, the higher the fl oat in the pipe. The position of the fl oat thus indicates the fl ow rate. (For details, see the fl ow diagram in the operating manual of the manufacturer.) Wittmann 101 / 301 fl ow controller Flow rate range per cycle 0-10 l/min (30 l/min) Temperature C [ F] 40 [104] 60 [140] 80 [176] Pressure bar [psi] 8 [116] 6 [87] 4 [58] EP6GB0FA EP6DE0FA 0510WT Chapter

64 Transport - Installation Blow-off valve: The blow-off valve is installed in the lower distribution channel of the cooling water battery. This valve is used to blow out the water from the cooling channels prior to a mould change. This is done to prevent corrosion (caused by escaping water) in the cooling channels and on the mould surfaces in the mould store. A compressed air hose is connected to the G 1/4" fi tting. By opening the stop valve, the water in the hoses and the mould is blown out. This ensures clean and dry mould change. Procedure: Close the water inlet line. Open the compressed air stop valve. By opening the regulating valves of the individual circuits (feed and return) and closing the other circuits, you can now blow out one circuit after the other, until all water is removed from the sight tube Oil cooling system (optional) The hydraulic oil is cooled in a heat exchanger. In the oil cooler, the cooling water is fed through cooling coils installed in the hydraulic oil reservoir. The cooling water fl ow rate is regulated by a pilot-controlled solenoid valve. It controls the cooling water fl ow based on the hydraulic oil temperature, ensuring that the oil is kept at a constant temperature. A temperature sensor in the hydraulic tank measures and monitors the oil temperature and transmits the measured values to the IMM control unit. Depending on these signals, the solenoid valve is opened or closed. Chapter EP6GB0FA EP6DE0FA 0510WT

65 Transport - Installation The water lines for the cooling of the hydraulic system must be installed by a specialist fitter. All fittings, lengths and cross-sections must meet the requirements! The cooling water hoses must be installed in such a way that proper and constant water infeed and return fl ow is ensured. Ensure that lines cannot become kinked or squeezed, restricting the cooling water fl ow. The hoses must be suitable for the specifi ed system pressure and ambient temperatures. For optimum effi ciency of the machine, the oil temperature should be between 45 C and 50 C (113 F and 122 F). The inlet water temperature must not exceed 30 C (86 F). Cooling water consumption: Water side max. 10 bar 145 psi Water 2 m/s 1,8 yd/s Heating/cooling unit Heating/cooling devices (optional) are used to adjust the temperature of the mould, the screw barrel, and/or the screw. Before operating the machine, read the safety instructions and operating manual for the injection moulding machine and the heating/cooling device! Heating/cooling devices must be installed and connected by a qualified electrician (in accordance with DIN VDE 0105 and IEC 364)! For the installation, connection and commissioning of the heating/cooling device, follow the instructions in the separate operating manual and refer to the wiring diagram in chapter Spare parts / plans. The relevant interfaces are located on the side of the switch cabinet. EP6GB0FA EP6DE0FA 0510WT Chapter

66 Transport - Installation Chapter EP6GB0FA EP6DE0FA 0510WT

67 Transport - Installation 4.12 Pneumatic system The compressed air lines for the pneumatic system must be installed and connected by a specialist technician. All fittings, lengths and cross-sections must meet the requirements! All work on the pneumatic system must be carried out by a specialist pneumatic technician! If the pneumatic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! Compressed air connection Compressed air is required for the movement of the injection unit and for the pneumatic shut-off nozzle (accessory equipment). The compressed air supply line must be equipped with a shut-off valve. Before carrying out out any maintenance work on the machine, close the supply lines. The compressed air must be supplied at a pressure of minimum 6 bar. Please refer to the general layout plans enclosed with the machine. EP6GB0GA EP6DE0GA 0510WT Chapter

68 Transport - Installation UNIFEED material feed unit UNIFEED material feed unit (optional) replaces the bulk material hopper, and does away with production stops for the fi lling of the hopper. The UNIFEED unit is the preferred feed option for the following materials: PE-HD, PE-LD, PS, PA, PA + GF, PP, ABS, POM, PPO. In general, the material feed unit is suitable for the feeding of regenerated material in conjunction with new granule material. The grain size must not exceed 3 to 4 mm (0.12 to 0.16"). If the material feed unit is installed above head level, use safe climbing aids and work platforms and comply with all relevant statutory safety regulations and instructions! Position the climbing aid in front of the injection moulding machine. Place the material feed unit on the hopper support and secure it with 2 screws (enclosed with unit). Align the suction lance to the retaining bores and the material container. Mount the air valve and the proximity switch and connect them according to the wiring diagram. Position the proximity switch directly at the acrylic glass and adjust it with the adjusting screw so that the LED is on when the container is full and is off when the container is empty. Connect the compressed air hose (DN 10 mm / 0.4") to the connecting piece and secure it with a hose clamp. The compressed air hose must be installed in such a way that the compressed air fl ow is not obstructed. Avoid kinking and squeezing of the hose. Ensure that the hose is long enough to cater for the travelling movements of the injection unit. The hose must be suitable for a system pressure of max. 7 bar / 101 psi and the expected ambient temperatures. Chapter EP6GB0GA EP6DE0GA 0510WT

69 Transport - Installation 4.13 Electrical equipment The machine may only be connected to a power supply which corresponds in phase, voltage and frequency to the data given on the electrical specification plate. Electrical installation may only be carried out by a qualified electrician (qualified to DIN VDE 0105 or IEC 364 or equivalent)! The electrical supply lines must be designed according to the specifications on the name plate! The currently valid local regulations on earthing and overload protection (overload, wrong polarity protection) in TN-, IT- or TT supplies must be observed without fail by the proprietor of the machine! The protection for the phase conductors and the neutral conductor (IT-supply) must be arranged to comply with the data on the electrical specification plate! Connection as "Classical zerorising" (PEN-conductor) must not be used. PE-conductor and N-conductor (if used) must always be connected separately! The connecting terminals for drive and heating are located in the switch cabinet. The phase conductors are connected directly to the main switch. It is possible to connect the machine with two separate supplies for the motor and heating circuits. If the machine is equipped with two separate power connections, they must not be connected to a joint supply line. Hence there are four connection schemes: 1 - Lead without neutral 1T2 1T1 1T3 4 (L1, L2, L3, PE) 2 - Lead with neutral 1T2 1T1 1T3 N 5 (L1, L2, L3, N, PE) EM6GB0HA EM6DE0HA 68WT Chapter

70 Transport - Installation 3 - Separate leads for drive and heating without neutral 1T2 2T1 2T3 1T1 1T3 2T2 4 (L1, L2, L3, PE) 4 (L1, L2, L3, PE) 4 - Separate leads for drive and heating with neutral 1T2 2T1 2T3 1T1 1T3 2T2 N 4 (L1, L2, L3, PE) 5 (L1, L2, L3, N, PE) Checking the direction of three phase motor of the mould height adjustment Before switching on the machine it must be ensured that: The switch cabinet must be closed. The guarding and safety gates must have been properly fitted and closed. ATTENTION If the direction of rotation is wrong, the mould height cannot be adjusted correctly and/or the clamping force cannto be controlled correctly! Connect the supplies; see paragraph "Electrical equipment". The hydraulic motor s direction of the three phase motor may only be tested by a qualified electrician (qualified to DIN VDE 0105 or IEC 364 or equivalent)! Open the electrical cabinet. Connect a phase sensor to lines 1L1, 1L2 and 1L3 on the main switch. Chapter EM6GB0HA EM6DE0HA 68WT

71 Transport - Installation Switch on the supply voltage (low voltage distribution). The phase sensor should now indicate a right-hand (clockwise) field. Switch off the supply voltage (low voltage distribution) if the direction of rotation is not correct and exchange two phases of the power connections 1L1, 1L2, and 1L3 of the mains lead in the switch cabinet. Close the switch cabinet. Only peripherical devices which correspond to the VDO requirements and the EMC regulations (electromagnetic compatibility) of electrical operating materials may be operated on the machine. Cabling which was additionally fitted to the machine by the proprietor must correspond to the EMC regulations (electromagnetic compatibility). EM6GB0HA EM6DE0HA 68WT Chapter

72 Transport - Installation Chapter EM6GB0HA EM6DE0HA 68WT

73 Mould mounting 5 Mould mounting 5.1 Preparation If the machine has a robot interface and the machine is to be run without the robot, then the latter should be switched off and the supplied dummy plug must be inserted. Operation of the machine without this linking out is not possible. The installation of the links is detailed under "Interfaces". It is a good idea to check the following before mounting a mould, to avoid unnecessary work: Mould height and dimensions must suit the machine. The sprue bush or hot runner radius must correspond to the machine nozzle radius. The centring flange must correspond to the centre bore in the nozzle and clamping platen. The length of the ejector bar and the ejector stroke must be compared with the machine specification (see chapter "Technical Data"). Check that the water fittings are the right size. The mould should have been checked for binding, seizing, missing or loose parts and badly adjusted slide valves. Water and air connections should be made to check for leakage. 5.2 Mould mounting The mould may only be mounted by an authorised skilled technician! 1 Switch on main switch. 2 Press and release the emergency stop buttons on the machine and robot, if present; the "Test emergency stop" error message will disappear 3 Turn on water supply to oil cooler 4 Check the safety device as described in the "Checking safety devices" paragraph. 5 Open and close all safety gates once (to test the safety gate monitoring). Press the "Open safety gate" and "Close safety gate" keys in case of a poweroperated safety gate (option). 6 The hydraulic drive and at the same time the oil pre-heating are switched on with the "Drive On" key EM6GB0IA EM6DE0IA 68WT Chapter 5-1

74 Mould mounting 7 After the control boots up the "Start page" screen page will appear. 8 Press the "Alarms" menu key; a list of the active error messages will be displayed, including the "Oil heating - Tolerance" error message. This error message disappears automatically as soon as the hydraulic oil comes up to operating temperature. See also the "Interrupt list" chapter in the " UNILOG B6 User manual". 9 An activation of the key symbol opens the window for "System password". 10 For the log on to the control refer to chapter A 7 in the control unit s manual. If further error messages are displayed, see the "UNILOG B6 User manual", "Interrupt list" chapter to find out how to clear them. Once all the errors are cleared and the drive is started, mould mounting can be continued. 11 Adjust the mould mounting height 11.1 Press the "Manual operation" key Press the "Injection unit back" key and move the injection unit (the nozzle) back. Chapter 5-2 EM6GB0IA EM6DE0IA 68WT

75 Mould mounting 11.3 Press the "Mould close" key and close the clamping platen, and check that the clamping platen is in the "Mould closed" position Check the position of the toggle. The toggle must have reached the locked out position Press the "Decrease mould height" key once (switches function on); yellow LED must light. Press "Decrease mould height" key again (performs function) Determine mould height (from drawing or by measurement) Press the "Increase mould height" key and move the platen back until the mould height is reached. 12 Clamping the mould on the nozzle platen 12.1 Press the "Mould open" key and open the clamping platen Press the "Setting mode" key; this avoids damaging the mould on initial opening. The mould may only be mounted by an authorised skilled technician! The lifting equipment must at least correspond to the weight of the mould. For details please refer to the manufacturer of the mould! 12.3 The mould halves must be prevented from sliding apart The mould must hang horizontally from the lifting equipment. EM6GB0IA EM6DE0IA 68WT Chapter 5-3

76 Mould mounting Danger of death! It must be ensured that no persons stand or linger under the suspended load! 12.5 Bring the mould into the open clamping unit Locate the mould in the nozzle platen s centring hole. (with the exception of circular discs - the rotary unit should be centered here!) 12.7 Position the mould square to the machine s lateral axis. ATTENTION The number of mould clamps must be adapted to the mould weight and the opening force of the machine! 12.8 Clamp the mould to the nozzle platen with mould clamps; it is essential to use bolts of the correct length; at least 1.5 D (= diameters of thread) must screw into the machine platen. = = = = The mould clamps (mounting elements for the mould; not supplied as standard with the machine) must be the same height as the thickness of the mould mounting platen, as otherwise there is a risk of the mould slipping. If necessary use proper washers. The above points apply equally to the mounting of a mould to mounting platens with T- slots. Chapter 5-4 EM6GB0IA EM6DE0IA 68WT

77 Mould mounting 12.9 Press the "Mould Close" key and close the clamping platen. 13 Clamping the mould to the clamping platen 13.1 Clamp the mould to the clamping platen with mould clamps; make sure the screws are the correct length; see step The lifting equipment should not be removed until the mould is bolted securely to both platens and this has been verified by an authorised technician! 13.2 Remove lifting gear from mould, mount the safety strap holding the two mould halves together, connect the ejector coupling (mould / hydraulic ejector cylinder) Press the "Mould open" key and open the clamping platen. 14 Set clamping force As the double toggle system can only achieve its full clamping force with the toggles locked out, the mould height and thus the clamp force must be adjusted after a mould change. To increase the clamping force (i.e. to reduce the mould height) the "Decrease mould height" key must be pressed. The clamp force is reduced by pressing the "Increase mould height" key. EM6GB0IA EM6DE0IA 68WT Chapter 5-5

78 Mould mounting 14.1 Press the "Manual operation" key Press the "Clamping unit" menu key. The "Clamping unit" page appears If the input field "Clamping force" is pressed, the "Numpad" appears. Here, the wished clamping force can be entered in "kn" (shtn) (see also User manual A5) Press "Mould open" key and crack the clamping platen open Press the "Decrease mould height" key: a second time if necessary (switch on / perform function). This closes the mould and an increase in clamp force is achieved Press the "Mould Close" key and close the clamping platen. Check whether the desired clamping force has been reached; the current clamping force will be displayed in green next to the "Clamping force" set value field. If the desired clamping force is still not reached, the procedure must be repeated from step 14.4 onwards This process is now repeated until the correct clamp force is achieved. The same procedure (steps 14.7 to 14.7) also applies for a reduction in clamping force. Press the "Mould open" key - press the "Increase mould height key". In this way the mould is opened and the clamp force reduced. Chapter 5-6 EM6GB0IA EM6DE0IA 68WT

79 Mould mounting 15 Log off from the control ATTENTION To prevent set value entries by unauthorised persons, the user must log off after finishing setting! 15.1 An activation of the key symbol opens the window for "System password". If you want to interrupt or finish your work at the control unit, you will have to logout first. This procedure prevents unauthorised input at the control unit Select the "Logout" key. If the logout is successful, the window is automatically closed. As an acknowledgement, user level 90 is displayed in the "User level symbol". 16 Connect the cavity pressure measuring (option) and temperature sensors. ATTENTION The cables must be laid and installed as not to be damaged by the mould or the machine. 17 Connect the mould heating and cooling. ATTENTION Please note the correct passage direction since the cooling may otherwise be subject to negative influences. The lines and cables must be laid and installed as not to be damaged by the mould or the machine. EM6GB0IA EM6DE0IA 68WT Chapter 5-7

80 Mould mounting 5.3 Quick-action mould mounting system Use the "Mouldfix" quick-action mould mounting system (option) to enable quick installation and dismantling while the injection mould will automatically be levelled. It may either be levelled horizontally or vertically depending on whether the injection moulds are to be installed laterally using a rolling truck or from above using a crane. Mould mounting 1 Switch on the machine as described in "Mould mouting", steps 1 to 10 (paragraph 5.2). 2 Adjust the mould mounting height as described in Step 11 (par. 5.2) "Adjusting the mould mounting height". 3 Press the "Setting mode" key. 4 Move clamping platen fully back. 5 Move injection unit fully back. Only then may the wedge clamping elements of the "Mouldfix" be moved out (released). 6 Switch on key-operated "Mouldfix" switch (Position 1) Move out (release) the wedge clamping elements of the "Mouldfix" for the nozzle and the clamping platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the movements of the clamping platen will be disabled. 8 The mould parts must be prevented from sliding apart. 9 Move the mould with the adapter platen of the nozzle unit into the nozzle platen s "Mouldfix" until reaching the limit stop. Chapter 5-8 EM6GB0IA EM6DE0IA 68WT

81 Mould mounting 10 Clamp the nozzle side part of the mould to the nozzle platen by activating the wedge clamping elements of the "Mouldfix" for the nozzle platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the movements of the clamping platen will be disabled. 11 Move the clamping platen slowly forward until the mould is closed and the clamping unit s entire adapter platen fits to the clamping platen. 12 Clamp the clamping unit s part of the injection mould to the clamping platen by activating the wedge clamping elements of the "Mouldfix" for the clamping platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the closing movement will be disabled. 13 Remove the safety devices for the preventing the injection mould from collapsing. 14 Switch off key-operated "Mouldfix" switch (Position 0). 0 1 Remove the key to protect the mould and prevent unauthorised reconnection. To dismantle the injection mould proceed in reversed order. The self-locking function of the wedge clamping elements prevents any part of the injection mould - even if the hydraulic pressure drops to zero - from disengaging automatically from the mould mounting platen. EM6GB0IA EM6DE0IA 68WT Chapter 5-9

82 Mould mounting 5.4 Magnetic quick-action mould mounting system The magnetic quick-action mould mounting system (option) is another option for quickly mounting or dismantling the mould. Use eccentric rings to centre the injection mould in the clamping and nozzle platen. At the same time the centering rings are to support the mould if the magnetic retention force is exceeded when opening the mould. Before mounting the mould the enclosed separate operating manual must be read. It contains information on safety equipment, requirements on the mould, mould mounting, commissioning, set value entries and maintenance. Mould mounting 1 Prepare the mould according to the operating instructions for the magnetic quick-action mould mounting system. 2 Switch on the machine as described in "Mould mouting", steps 1 to 10 (paragraph 5.2). 3 Adjust the mould mounting height as described in Step 11 (par. 5.2) "Adjusting the mould mounting height". 4 Press the "Setting mode" key. 5 Move clamping platen fully back. 6 Move injection unit fully back. 7 Check the contact surfaces of the magnetic contact surfaces and the mould for dents and eliminate them, clean them thoroughly and spray them with corrosion inhibitor. 8 Check whether magnetic modules have been demagnetised. Chapter 5-10 EM6GB0IA EM6DE0IA 68WT

83 Mould mounting 9 Centre mould on the nozzle platen as described in steps 12.2 to 12.6 (paragraph 5,2 Mould mounting). Magnetic field hazard. The magnetic field will almost close completely in the base plate of the mould (in a depth of 12 mm / 0.47 inch). However, when in immediate proximity, it may influence sensitive devices such as cardiac pacemakers, hearing aids, disks, etc.! ATTENTION The power of the magnetic modules amounts to up to 16 kg / cm 2 (5,58 lb / sq.in.). During magnetising an object between the mould and the magnetic module will be uncontrollably clamped and damaged! 10 Ensure that thereare no magnetisable objects (e.g. spanners) within the clamping unit area. 11 Magnetise the nozzle unit s magnet mounting plate. 12 Check the clamping procedure; the respective pilot lamp must light up on the control panel or the manual operation unit. 13 Remove lifting gear from mould. 14 Press the "Mould Close" key and close the clamping platen. 15 Magnetise the clamping unit s magnet mounting platen. 16 Check the clamping procedure; the green pilot lamp must light up on the control panel or the manual operation unit. 17 Remove the safety strap holding the two mould halves together. EM6GB0IA EM6DE0IA 68WT Chapter 5-11

84 Mould mounting 5.5 Interfaces The interfaces and sockets for ancillaries are located in the switch cabinet (Option). Details of installation, connection and commissioning are to be found in the appropriate Operating Manuals. Before operating the machine with peripheral equipment, it is essential that the safety regulations and operating manual of these devices are followed! Electrical installation may only be carried out by a qualified electrician! For some peripheral equipment a dummy plug must be used in the interface when the machine is operated without the peripheral equipment. See also the appropriate wiring diagrams in "Spare parts / plans" chapter. Before switching on the emergency stop buttons should be released by rotating a quarter turn clockwise and program selection switches set to the required position. The start impulse for automatic operation of a peripheral device is given by starting an automatic cycle of the machine. Automatic operation is ended by operating an emergency stop button or by switching off or changing the automatic cycle of the machine. 5.6 Checking the safety devices The safety devices can only fulfil their purpose if their faultless operation can be guaranteed. Therefore it is necessary to check the following for effective function before operation: The function test for the safety device may only be carried out by a trained and skilled technician! Electrical closing interlock: Proper function and securely fixed limit switches. Hydraulic interlock: Proper function and securely fixed limit switch. Mechanical scotch (option): Proper function and free movement of scotch (flag) on the clamping platen and the correct position (teeth) of the scotch bar as well as the secure fitting of the limit switch. Chapter 5-12 EM6GB0IA EM6DE0IA 68WT

85 Mould mounting If a fault appears on the machine which causes the mechanical scotch to come into operation, Battenfeld Customer Service or the responsible agent must be contacted. Purge guard: Function, free movement and securely fixed limit switche Purge guard, safety gate and guarding: Security of all fixing bolts and undamaged condition and proper function 5.7 Test run and interlock test Operating and other personnel may only stand in front of the machine on the operator s side during operation! It is forbidden to stand on the machine or to reach into the injection unit during operation! Install required safety devices. The safety regulations in the chapter "Safety" are to be followed without fail! After electrical installation safety devices are to be tested Check hydraulic lines and components for leaks Check all visible fittings for security Close safety gates and check for proper fitting Clear inside of the machine of all foreign bodies (forgotten mould) Set peripheral equipment to the starting position, i.e. the position in which no damage to it or to machine components is possible. Turn on water supply to oil cooler Check function of safety devices. ATTENTION It is essential to select "Setting" mode, or else the test run may damage the mould! Check the movements of the various units as follows: Switch on main switch (to "1"). Check the safety device as described in the "Checking safety devices" paragraph. EM6GB0IA EM6DE0IA 68WT Chapter 5-13

86 Mould mounting Open and close the clamping unit s safety gate (to check the safety gate monitoring). Switch on drive ("Drive On" key). Press the "Open safety gate" and "Close safety gate" keys in case of a power-operated safety gate (option) and open and close the safety gates entirely. Start the pump without load and run it for a few seconds to allow for adequate lubrication. Press the "Setting mode" key. Assuming that the mould has been left in the "Mould closed" position after mould mounting, open it with the "Mould open" key. The movements of the other units (ejector, screw and nozzle) can now be checked and their functions tested. Chapter 5-14 EM6GB0IA EM6DE0IA 68WT

87 Design and function 6 Design and function Clamping unit 6.2 Injection unit 6.3 Hydraulic system (optional) 6.4 Pneumatic system (optional) 6.5 Airmould (optional) 6.6 Electrics 6.7 Control system EP6GB0JA EP6DE0JA 1209WT Chapter 6-1

88 Design and function Chapter 6-2 EP6GB0JA EP6DE0JA 1209WT

89 Design and function 6.1 Clamping unit Technical description The clamping unit consists essentially of the clamping plate (1) with mounted hydraulic or servoelectric ejector (2), the nozzle plate (3), the front plate (4), the motor for the clamping movement (5) and the beams (6), the toggle (7) with the low-maintenance guide bushings (8) and the height adjusting unit (9). The entire clamping unit is designed as a self-supporting assembly that is permanently fi xed to the machine frame through screws in the nozzle plate. To ensure unhindered expansion of the beams, the front page is not fi xed with screws to the machine frame. The moving clamping plate is guided by the clamping plate support on the machine frame. A rotary encoder in the motor of the clamping unit records the travelling movement of the clamping plate and transfers the data to the injection moulding machine control system. The clamping force is applied through a 5-point toggle system, which is driven by a directly connected spindle motor. This ensure high travelling speeds at minimum energy consumption. The clamping force is monitored by a proximity switch ( contact-free limit switch). EP6GB0KA EP6DE0KA 0510WT Chapter 6.1-1

90 Design and function The low-maintenance guide system of the clamping plate located above the beams and the support of the clamping plate ensure that the plate is kept in a perfect horizontal position during the entire stroke. The mould height can be adjusted by means of the hydraulically operated height adjusting unit, whose adjusting speed can be programmed depending on the operating status. This means that the setup procedure can be completed in very short times. The minimum and maximum mould heights are monitored by two limit switcheslocated on the machine operating side. The hydraulic ejector is mounted in the clamping plate and is designed as a double-acting hydraulic cylinder. The stroke transducer records the travelling movement of the ejector and transfers the data to the machine control system Lubrication of toggle system The automatic central lubrication system for adhesive oil supplies the connected lube points at regular intervals with an exactly metered amount of adhesive oil. The lubrication intervals depend on the cycles of the machine and can be changed through the control system. Factory-set lubrication intervals: EcoPower lubricant quantity Rotary table diameter Lube points Number of lubrication processes Amount of lubricant (ccm / 2 lubrication cycles) 0,92 0,92 1,8 1,8 1,8 Lubrication cycle duration (sec.) Lubrication intervals Amount of lubricant (l) / 1 million cycles 0,14 0,18 0,36 0,51 0,6 Chapter EP6GB0KA EP6DE0KA 0510WT

91 Design and function The central lubrication system for adhesive oil consists mainly of a pump unit with a gear pump, a container, the piston distributors and the lubricant lines. The pump unit is started automatically as soon as the machine is switched on by the main switch. After 3 to 15 seconds, the pump has established the operating pressure. After another 15 seconds, it is switched off and the system is depressurised. At this point, the lubrication process is completed. After the preset number of cycles, which correspond to the working cycles of the machine, the control system switches on the pump again to complete the next lubrication process. The piston distributors meter and distribute the oil fed by the pump through the main line. Each lube point is assigned its own piston distributor. The piston distribution features a distribution piston whose cylinder is fi lled in front of the piston with the oil indented for the respective lube point. The oil volume is metered by the metering nipple. This nipple is screwed into the piston distributor and limits the stroke of the distribution piston. When the pump is started, the oil pushes the distribution piston in the piston distributor forward against the metering nipple, and the oil in front of the piston is pressed with the pump pressure to the lube point. As soon as the pump is switched off, the oil pressure in the main line drops and the distribution piston returns to its initial position. At this point, the oil for the next lubrication interval is fed into the distribution piston cylinder. The amount of oil supplied to the lube points can be adjusted by changing the lubrication interval at the pump unit. The oil level in the container of the pump unit must be checked daily. It must not drop below the min mark (for oil quality specifi cations, see chapter Maintenance ). EP6GB0KA EP6DE0KA 0510WT Chapter 6.1-3

92 Design and function Central lubrication pump Design: 1 DC motor 2 Screw drive 3 Eccentric shaft 4 Piston 5 Piston outlet screw 6 Delivery piston 7 Grease screen 8 Agitator blade 9 Grease container 10 Secondary piston 11 Conical helical spring 12 Tracer pin 13 Overfi ll safety device 14 Pressure-relief valve Connection signalling device/control unit Anschluss Signalgeber / Steuergerät Central lubrication pump without control unit Chapter EP6GB0KA EP6DE0KA 0510WT

93 Design and function Functional description The central lubrication pump is an electric lubricant pump. The pump is equipped with a fi lling level sensor as standard. To ensure that no air is taken in by the system, the pump is automatically switched off when the minimum grease level is reached. The lubrication intervals depend on the working cycles of the machine. Factory-set lubrication intervals: EcoPower lubricant quantity Rotary table diameter 55 HY 110 HY 180 HY 55 SE 110 SE 180 SE Lube points Number of lubrication processes Amount of lubricant (ccm / 2 lubrication cycles) 0,29 0,29 0,35 0,44 0,44 0,5 Lubrication cycle duration (sec.) Lubrication intervals Amount of lubricant (l) / 1 million cycles 0,12 0,29 0,7 0,18 0,44 1 EP6GB0KA EP6DE0KA 0510WT Chapter 6.1-5

94 6.1.4 Turn-out device Design and function The hydraulically powered motor of the turn-out device (1) is mounted on the clamping plate in the place of the hydraulic ejector. The hydraulic ejector is supplied as a separate assembly. All work on the hydraulic system must be carried out by a specialist hydraulic technician! Always strictly adhere to the safety instructions in chapter Safety! If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! Turn the Pressure relief key switch. In machines with hydraulic core puller, ejector, etc. with quick-release couplings, the hydraulic system must be completely depressurised by means of the key switch before the hose lines are disconnected. Shut down the machine as described in chapter Operation, section Shutting down machine. Disconnect the mechanical connection between the mould and the turn-out device. 1 Thoroughly clean the area around the connecting points of the hydraulic hose connections and the fi ttings at the rear side of the machine. Disconnect the hydraulic lines of the turn-out device. Collect residual oil in a suitable container. Seal the hydraulic connections of the turn-out device with suitable plugs. Remove the screws and the turn-out device. Mount the hydraulic ejector by completing the above steps in reverse order. Chapter EP6GB0KA EP6DE0KA 0510WT

95 Design and function Mechanical closing guard CAUTION The mechanical closing guard (optional) prevents the clamping plate from closing when the safety gate is open. The mechanical closing guard consists mainly of a stop bar equipped with saw-type teeth, the stop, the stroke solenoid or pneumatic stroke cylinder and a position monitoring unit. The mechanical closing guard is a safety device designed to prevent accidents. It can only work properly, if all its components are in proper working order and the parts can move freely. Please note that the stop surface against which the tooth of the stop bar is pressed when in locking position is exposed to wear. Timely replacement of the stop helps prevent malfunctions of the mechanical closing guard! The stop bar is mounted at the operating side of the clamping plate and slides through the stop tube, which is attached to the front plate. The stop tube is equipped with a stroke solenoid of pneumatic stroke cylinder with stop. The stop touches the stop bar as long as the stroke solenoid or the pneumatic stroke cylinder is not actuated. When the safety doors are closed, the stroke solenoid of the pneumatic stroke cylinder lift the swivelling stop. As soon as one of the safety doors is opened, the power supply is interrupted and the stroke solenoid of the pneumatic stroke cylinder returns to its neutral position. The stop is lowered and positioned in front of a tooth of the stop bar, thus preventing the clamping plate from clamping. EP6GB0KA EP6DE0KA 0510WT Chapter 6.1-7

96 Design and function Chapter EP6GB0KA EP6DE0KA 0510WT

97 Design and function 6.2 Injection unit Technical description Nozzle pressure cylinder 2 Guide of hopper base 3 Guide rails of injection unit 4 Material feed block 5 Screw barrel, shaft and mount 6 Injection spindle 7 Linear guides of injection drive 8 Screw lock EP6GB0LA EP6DE0LA 0510WT Chapter 6.2-1

98 Design and function The injection unit consists of the screw barrel in which the material is melted and from which it is injected into the mould. It further includes a material hopper into which the raw material to be injection-moulded is fi lled, normally in the form of granules. The feed zone is water-cooled to prevent the melted material from becoming stuck in the material feed zone. The screw barrel is equipped with heating bands for plasticising. The screw transports the raw material from the hopper to the head of the screw barrel. In the process, the material is plasticised and homogenisd. As the plasticised material collects in front of the screw tip, the screw is pushed backwards, until the set plasticisation path is reached and screw rotation is stopped. After the mould has been closed and the clamping force is established, the actual injection process is started. At this point, the entire screw is pushed forward like a piston and the plasticised material is injected under high pressure through the nozzle into the mould. The nozzle consists of a nozzle head and a nozzle body and connects the screw barrel with the mould. The screw barrel is secured by a yoke. The injection and plasticisation is carried out by means of water-cooled servo motors and a toothed belt drive. During injection, the force is transferred through a ball-type linear drive. The injection unit is mounted on a linear guide. It is moved forward and back by means of a hydraulic or servo-electric nozzle pressure cylinder. Chapter EP6GB0LA EP6DE0LA 0510WT

99 Design and function Centring of nozzle Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations! Never use machine components as climbing aids! When working at height, wear fall arrest gear! Use only tools and equipment that cannot cause damage to the components described below! Risk of injury and damage to components! Use only components (nozzle, screw, screw barrel, fixing screws) that have been supplied by Battenfeld or meet the Battenfeld specifications. For the tightening torques of the screws, see chapter Technical data, section 2.13 and the spare parts list. 1 Heat the cylinder. 2 Remove the paneling from the injection unit. EP6GB0LA EP6DE0LA 0510WT Chapter 6.2-3

100 Design and function 3 Detach the screw (4) from the screw coupling. Loosen the 4 screws (1) of the screw coupling (2) and remove the 2 feather keys (3) Press the Setup mode button. Chapter EP6GB0LA EP6DE0LA 0510WT

101 Design and function 5 Actuate the button for injection piston movement until the nozzle tip (5) is in line with the nozzle plate (6) Using a caliper gauge, determine the horizontal eccentricity of the nozzle by repeatedly measuring the distance from the nozzle bore to the mould centring bore. The offset must not exceed 0.2 mm (0.008"). EP6GB0LA EP6DE0LA 0510WT Chapter 6.2-5

102 Design and function 7 To move the nozzle in horizontal direction to the centre, loosen the top screws (7) on the adjusting block (8). Loosen the lock nut (9) and the adjusting screws (10) to the left and right on the adjusting block (8). Depending on the direction in which the nozzle is to be moved, turn the lateral screws in or out After the nozzle is properly aligned in horizontal direction, tighten the lock nut (9) and the adjusting screws (10) and the top screws at the adjusting block (7). Chapter EP6GB0LA EP6DE0LA 0510WT

103 Design and function 9 Using a caliper gauge, determine the vertical position of the nozzle by repeatedly measuring the distance from the nozzle bore to the mould centring bore. The offset must not exceed 0.2 mm (0.008"). 10 To align the nozzle horizontally, loosen the lock nut (11) at the adjusting block (8) and adjust the height with the grub screw (12) After the nozzle height has been adjusted, retighten the lock nut (11). 12 After completion of the adjustment, check the nozzle position again. EP6GB0LA EP6DE0LA 0510WT Chapter 6.2-7

104 Design and function Nozzle change Operating data of shut-off nozzles Herzog Typ SHP Activation Spring max. injection fl ow (ccm/sec./cinch/ sec.) (PS) Working data Shut-off nozzles Nozzle contact force max. (kn/ sh ton) Back pressure (bar/psi) 290 / 4200 Injection pressure max. (bar/psi) Temperature max. ( C/ F) System pressure pneum./hydr. (bar/psi) Lever length/ stroke (mm/inch) Herzog Typ HP0 pneum./integrated 500 / / 30,50 70 / 7,87 6,0 / 87 Herzog Typ HP0 pneum./external 500 / /3,03 // 17/0,7 Herzog Typ HP0 hydr./external 500 / / /3,03 // 17/0,7 Herzog Typ HP1 pneum./integrated 150 / ,0 / 87,0 Herzog Typ HP1 pneum./external 150 / ,0 / 58 77/3,03 // 12/0,5 Herzog Typ HP1 pneum./external 1600 / 97, / 14, / / / 752 4,0 / /4,56 // 22/0,9 Herzog Typ HP1 hydr./external 150 / / /3,03 // 12/0,5 Herzog Typ HP1 hydr./external 250 / / /4,56 // 22/0,9 Herzog Typ HP2 pneum./integrated 250 / ,0 / 87, / 213, / 20,23 Herzog Typ HP2 hydr./external 350 / / /4,85 // 32/1,25 Herzog Typ BHP0 pneum./integrated 1600 / 97, / 14, / ,0 / 87,0 Herzog Typ BHP1 pneum./integrated 500 / 30,50 46 / 5, / ,0 / 87,0 ENG Typ L20 pneum./integrated 1000 / / 11,24 ENG Typ L30 pneum./integrated 3500 / 213, / 14, / / / 752 6,0 / 752 PSG Typ G30 Spring 250 / 3625 PSG Typ G30 pneum./external 200 / 12,2 90 / 10,1 250 / ,0 / 58 35/1,38 // 8/0,31 PSG Typ G30 hydr./external 350 / / /1,38 // 8/0,31 PSG Typ G48 Spring 250 / 3625 PSG Typ G48 pneum./external 250 / ,0 / 87,0 35/1,38 // 5/0, / / 752 PSG Typ G48 pneum./external 500 / 30, / 11, / ,0 / 87,0 60/2,36 // 8/0,32 PSG Typ G48 hydr./external 350 / / /1,38 // 5/0,20 PSG Typ G48 hydr./external 350 / / /2,36 // 8/0,32 PSG Typ G70 Spring 250 / / 97, / 14,61 PSG Typ G70 pneum./external 350 / ,0 / 87,0 90/3,52 // 10/0,40 Adjustment of external pneumatic/hydraulic shut-off cylinder: Nozzle closed: The needle touches the nozzle tip, the piston of the shut-off cylinder is in fl oating position - minimum distance to machine > 1mm Nozzle open (Herzog system): The needle shoulder touches the nozzle body, the lever is lifted from the needle but does not touch the basic body; the piston of the shut-off cylinder is in its end position at the machine Nozzle open (Fuchslocher system): The needle with the crossbar touches the nozzle body, the lever with the rollers is lifted by > 1mm from the crossbar; the piston of the shut-off cylinder is in its end position at the machine Guide values for lever travel - shut-off cylinder adjusting stroke - see table Chapter EP6GB0LA EP6DE0LA 0510WT

105 Design and function Basic conditions for nozzle change 1 Press the Manual mode button. 2 Set the peripheral equipment (optional) to their initial position and switch them off, following the instructions in the respective operating manuals. 3 Switch off the material feed unit (optional). ( ) For Airmould nozzle only: close the nitrogen supply to the Airmould pressure unit. If necessary, shut down the Airmould nitrogen generator following the instructions in the separate operating manual. Shut down the Airmould pressure unit following the instructions in the separate operating manual. For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations! Never use machine components as climbing aids! When working at height, wear fall arrest gear! 4 Position the climbing aid in front of the machine. 5 Remove the bulk hopper from the feed opening of the screw barrel. 6 Move the core pullers (optional) out of the mould. Move out core puller indicates that the injection moulding has been removed from the mould or has been ejected by the ejector. 7 Move the clamping plate to its initial position (mould open). 8 If necessary, use the ejector to remove the injection moulding from the mould. EP6GB0LA EP6DE0LA 0510WT Chapter 6.2-9

106 9 Switch on the screw barrel heating to the currently set operating temperature. Design and function 10 Press the Injection unit back button until there is suffi cient space in front of the nozzle to eject the residual plasticised material. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! 11 Open the protective guard of the nozzle. 12 Place a suitable container in front of the nozzle. Risk of injury from crushing during closing of the injection guard. Limbs might be crushed or caught between the injection guard and the nozzle plate! 13 Close the protective guard of the nozzle. 14 Eject the residual plasticised at short intervals. 15 Flush the screw barrel with a suitable cleaning compound. For a list of suitable agents, contact the manufacturer of the plastic you are using. 16 Switch off the water system, the pneumatic system and the Airmould modular system (optional). For details, see chapter Operation, section Shutting down machine. 17 Press the Injection unit back button until there is suffi cient space for the dismantling of the nozzle. For Airmould nozzles only: If the nitrogen system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! For Airmould nozzle: ( ) Depressurise the Airmould modular system. For detailed instructions, refer to the operating manual of the Airmould modular system (chapter Transport - Installation, section Preparation for empty run and locking test without material ). ( ) Set the main switch at the control cabinet of the Airmould modular system to OFF and secure it against inadvertent switching on. Chapter EP6GB0LA EP6DE0LA 0510WT

107 Design and function 17 Switch off the nozzle and screw barrel heating, 18 Switch off the hydraulic system ( Hydraulic Stop button). 19 Shut off the machine at the main switch and secure the switch with a padlock against inadvertent switching on. The main switch should only be actuated if there is no load. 20 Open the protective guard of the nozzle. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The nozzle must be dismantled and installed by an authorised specialist technician! For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations! Never use machine components as climbing aids! When working at height, wear fall arrest gear! CAUTION Use only tools and equipment that cannot cause damage to the components of the machine! The next steps in the procedure are described below in separate chapters for each nozzle design EP6GB0LA EP6DE0LA 0510WT Chapter

108 Design and function Changing open nozzle Fig. 1 Open nozzle Requirements: items 1-20 (chapter ) Dismantle the heating band of the nozzle (1). 2 Remove the nozzle (1) with a hex wrench placed on the hex head (2). For Airmould nozzles only: Remove the union nut of the nitrogen pressure line from the nozzle body. 3 Remove the nozzle body with a hex wrench placed on the hex head (2). Risk of fire! Do not use flammable solvents! 4 Carefully clean the nozzle (1) and the nozzle body,using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Chapter EP6GB0LA EP6DE0LA 0510WT

109 Design and function 5 Treat the threads of the new or cleaned nozzle (1) with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces for damage or wear. Before inserting a new nozzle (1), check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle (1)). 6 Screw in the nozzle body by hand to the stop but do not tighten it. 7 Screw in the nozzle (1) by hand to the stop but do not tighten it. 8 Mount the heating band of the nozzle (1). 9 Switch on the main switch. 10 Switch on the hydraulic system ( Hydraulic Start button). 11 Switch on the heating of the nozzle (1) and the screw barrel and heat it to operating temperature. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 12 After heating the assembly to operating temperature, fi rmly tighten the nozzle body and the nozzle (1). For tightening torques, see chapter Technical data. For Airmould nozzles only: Screw on the union nut of the nitrogen pressure line at the nozzle body until there is a clear effort required to tighten it further. Risk of injury from crushing during closing of the injection guard. Limbs might be caught between the injection guard and the nozzle plate! 13 Close the protective guard of the nozzle (1). For Airmould nozzles only: Switch on the main switch at the switch cabinet of the Airmould modular system. Pressurise the nitrogen pressure line and check the union nut for leakage. For detailed instructions, refer to the operating manual of the Airmould modular system (chapter Maintenance, section Nitrogen leakage ). EP6GB0LA EP6DE0LA 0510WT Chapter

110 Changing Herzog type SHP needle shut-off nozzle spring-controlled Design and function Body 2 Needle guide bushing 3 Fixing pin 4 Thrust ring 5 Spring pack 6 Adapter 7 Shut-off needle 8 Nozzle head 9 Heating band 10 Temperature sensor Chapter EP6GB0LA EP6DE0LA 0510WT

111 Design and function Requirements: items 1-20 (chapter ) 1 Remove the temperature sensor, if installed. 2 Dismantle the heating band (9) of the nozzle. 3 Screw out the nozzle head (8). 4 Pull out the shut-off needle (7). 5 Unscrew the adapter (6). Risk of fire! Do not use flammable solvents! 6 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 7 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). EP6GB0LA EP6DE0LA 0510WT Chapter

112 Design and function 8 Mount the needle shut-off nozzle by completing the above steps in reverse order. 9 Screw in the adapter (6) by hand to the stop but do not tighten it. 10 Push in the shut-off needle (7). 11 Screw in the nozzle head (8) by hand to the stop but do not tighten it. 12 Mount the heating band (9) of the nozzle. 13 Screw in the temperature sensor (10) by hand to the stop but do not tighten it. 14 Switch on the main switch. 15 Switch on the hydraulic system ( Hydraulic Start button). 16 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 17 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor. Tightening torques: Nozzle head (8) Nm (162 ft lb) Fixing pin (3) - 3 Nm (2 ft lb) Body (1) Nm (125 ft lb) For the tightening torque of the adapter (7) see chapter Technical data. Risk of injury from crushing during closing of the injection guard. Limbs might be crushed or caught between the injection guard and the nozzle plate! 18 Close the protective guard of the nozzle. Chapter EP6GB0LA EP6DE0LA 0510WT

113 Design and function Changing Fuchslocher needle shut-off valve Nozzle body 2 Spring chamber 3 Compression spring 4 Heating band 5 Shut-off needle 6 Nozzle head Requirements: items 1-20 (chapter ) 1 Unscrew the temperature sensor. 2 Dismantle the heating band (4) from the nozzle head (6). 3 Remove the nozzle body (1) with a hex wrench placed on the hex head. Do not dismantle the spring chamber (2). The manufacturer shall not be liable for damage caused by incorrect dismantling or installation. If you suspect that the needle shut-off valve is not working properly, contact our customer service. For addresses, see chapter Customer service. EP6GB0LA EP6DE0LA 0510WT Chapter

114 Design and function Risk of fire! Do not use flammable solvents! 4 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is the cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 5 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). 6 Screw in the nozzle body (1) by hand to the stop but do not tighten it. 7 Mount the heating band (4) of the nozzle. 8 Screw in the temperature sensor. 9 Switch on the main switch. 10 Switch on the hydraulic system ( Hydraulic Start button). 11 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. Chapter EP6GB0LA EP6DE0LA 0510WT

115 Design and function Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 12 After heating the assembly to operating temperature, fi rmly tighten the nozzle and the nozzle body. Tightening torques: Nozzle head (6) to 350 Nm (221 to 258 ft lb) Nozzle body (1) to 400 Nm (258 to 295 ft lb) Risk of injury from crushing during closing of the injection guard. Limbs might be crushed or caught between the injection guard and the nozzle plate! 13 Close the protective guard of the nozzle. EP6GB0LA EP6DE0LA 0510WT Chapter

116 Design and function Changing Herzog type HP needle shut-off nozzle (pneumatically or hydraulically operated) with integrated control cylinder Nozzle head 2 Shut-off needle 3 Fixing pin 4 Lever bolt 5 Levers 6 Screws 7 Heating band 8 Temperature sensor 9 Adapter 10 Yoke /adapter ring 11 Control cylinder Chapter EP6GB0LA EP6DE0LA 0510WT

117 Design and function Requirements: items 1-20 (chapter ) 1 Remove the temperature sensor (8), if installed. 2 Remove the heating band (7) of the nozzle. 3 Disconnect the pneumatic and hydraulic hoses (depending on model) from the control cylinder (11) and remove the lever (5). 4 Screw off the nozzle head (1). 5 Pull out the shut-off needle (2). 6 Screw off the adapter (9). Risk of fire! Do not use flammable solvents! 7 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 8 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). EP6GB0LA EP6DE0LA 0510WT Chapter

118 Design and function 9 Mount the needle shut-off nozzle by completing the above steps in reverse order. 10 Screw in the adapter (9) by hand to the stop but do not tighten it. 11 Insert the shut-off needle (2). 12 Screw in the nozzle head (1) by hand to the stop but do not tighten it. 13 Mount the heating band (7) of the nozzle. 14 Screw in the temperature sensor (8) by hand to the stop but do not tighten it. 15 If the control cylinder (11) is not in the required position after being screwed in (e.g. if control cylinder (11) protrudes vertically), loosen the 12 screws (6) by 4 revolutions and then adjust the control cylinder (11) position by turning it clockwise Turn clockwise Tighten two opposite screws (6) and check the gap between the body and the adapter ring (max. permissible gap width 2.5 mm (0.1")). Chapter EP6GB0LA EP6DE0LA 0510WT

119 Design and function 17 Tighten all screws cross-wise. Torque HP0 HP1 HP2 1st step Prefixing Prefi xing Prefi xing 2nd step 7 Nm 15 Nm 35 Nm 3rd step 10 Nm 22 Nm 45 Nm 4th step 12 Nm 25 Nm 50 Nm 18 Connect the pneumatic and hydraulic hoses (depending on model) to the control cylinder (12) and mount the lever (5). 19 Switch on the main switch. 20 Switch on the hydraulic system ( Hydraulic Start button). 21 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 22 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor. Tightening torques: Designation Torque HP0 HP1 HP2 Screws 12 Nm (9 ft lb) 25 Nm (18 ft lb) 50 Nm (37 ft lb) Head 220 Nm (162 ft lb) 500 Nm (369 ft lb) 1200 Nm (885 ft lb) Heater band screws by hand by hand by hand Temperature probe by hand by hand by hand 23 Close the protective guard of the nozzle. Risk of injury from crushing during closing of the injection guard. Limbs might be caught between the injection guard and the nozzle plate! EP6GB0LA EP6DE0LA 0510WT Chapter

120 Design and function Changing Herzog type BHP bolt shut-off nozzle (pneumatically controlled) with integrated control cylinder Nozzle head 2 Bolt shut-off mechanism 3 Lever bolt 4 Levers 5 Screws 6 Heating band 7 Temperature sensor 8 Adapter 9 Yoke /adapter ring 10 Control cylinder 11 Shut-off nut 12 Body Chapter EP6GB0LA EP6DE0LA 0510WT

121 Design and function Requirements: items 1-20 (chapter ) 1 Remove the temperature sensor (7), if installed. 2 Remove the heating band (6) of the nozzle. 3 Disconnect the pneumatic and hydraulic hoses (depending on model) from the control cylinder (10) and remove the lever (4). 4 Screw out the nozzle head (1). 5 Screw off the adapter (8). 6 Remove the shut-off nut (11). 7 Remove the bolt shut-off mechanism (2). The bolt and bolt bushing are sometimes difficult to remove. Do not apply excessive force. If you encounter any problems in removing these parts, contact Herzog. Carefully drive out the bolt from the bottom, using a mandrel. Remove the bushing and the bolt from the top. Align the grooves of the bolt bushing with the positioning pin to the body. EP6GB0LA EP6DE0LA 0510WT Chapter

122 Design and function Risk of fire! Do not use flammable solvents! 8 Carefully clean the components of the nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 9 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). 10 Mount the bolt shut-off nozzle by completing the above steps in reverse order. 11 Screw in the adapter (8) by hand to the stop but do not tighten it. 12 Insert the bolt lock (2) and tighten the shut-off nut (11). 13 Screw in the nozzle head (1) by hand to the stop but do not tighten it. 14 Mount the heating band (6) of the nozzle. 15 Screw in the temperature sensor (7) by hand to the stop but do not tighten it. 16 Connect the pneumatic and hydraulic hoses (depending on model) to the control cylinder (10). 17 Switch on the main switch. 18 Switch on the hydraulic system ( Hydraulic Start button). 19 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. Chapter EP6GB0LA EP6DE0LA 0510WT

123 Design and function Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 20 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor. Tightening torques: Shut-off nut (11) Nm (133 ft lb) Screws (5) - 25 Nm (18 ft lb) Bolt screws (11) - 30 Nm (22 ft lb) Nozzle head (1) Nm (111 ft lb) 21 Close the protective guard of the nozzle. Risk of injury from crushing during closing of the injection guard. Limbs might be caught between the injection guard and the nozzle plate! EP6GB0LA EP6DE0LA 0510WT Chapter

124 Changing Herzog type HP needle shut-off nozzle (pneumatically or hydraulically operated) Design and function Adapter 2 Temperature sensor 3 Heating band 4 Nozzle head 5 Screws 6 Rods Requirements: items 1-20 (chapter ) 1 Remove the temperature sensor (2), if installed. 2 Dismantle the rods (6). 3 Dismantle the heating band (3) of the nozzle. 4 Screw out the nozzle head (4). 5 Pull out the shut-off needle. 6 Screw off the adapter (1). Chapter EP6GB0LA EP6DE0LA 0510WT

125 Design and function Risk of fire! Do not use flammable solvents! 7 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 8 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). 9 Mount the needle shut-off nozzle by completing the above steps in reverse order. 10 Screw in the adapter (10) by hand to the stop but do not tighten it. 11 Insert the shut-off needle (2). 12 Screw in the head (1) by hand to the stop but do not tighten it. 13 Mount the heating band (8) of the nozzle. 14 Screw in the temperature sensor (9) by hand to the stop but do not tighten it. EP6GB0LA EP6DE0LA 0510WT Chapter

126 Design and function 15 Switch on the main switch. 16 Switch on the hydraulic system ( Hydraulic Start button). 17 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 18 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor. Tightening torques: Designation Torque HP0 HP1 HP2 Screws 12 Nm (9 ft lb) 25 Nm (18 ft lb) 50 Nm (37 ft lb) Head 220 Nm (162 ft lb) 500 Nm (369 ft lb) 1200 Nm (885 ft lb) Heater band screws by hand by hand by hand Temperature probe by hand by hand by hand 19 Mount the rods (6). 20 Close the protective guard of the nozzle. Risk of injury from crushing during closing of the injection guard. Limbs might be caught between the injection guard and the nozzle plate! Chapter EP6GB0LA EP6DE0LA 0510WT

127 Design and function The nozzle is supplied as pre-assembled unit. The final assembly is done directly on the machine. After the rods with the nozzle has been aligned, tighten the fl ange screws crosswise in 4 steps. The gap between the body and the adapter ring might measure 0.5 to 2.5 mm (0.02 and 0.1"). Gap between body and adapter ring Flange screws Rods Tighten the screws crosswise. 1st tightening step = tighten all screws equally (preliminary fi xture) 2nd tightening step = tighten with 70% of prescribed torque 3rd tightening step = tighten with 90% of prescribed torque 4rth tightening step = tighten with 12 Nm (9 ft lb) EP6GB0LA EP6DE0LA 0510WT Chapter

128 Design and function Changing Fuchsloser needle shut-off nozzle (pneumatically or hydraulically operated) Nozzle body 2 Thrust ring 3 Heating band 4 Nozzle head 5 Shut-off needle 6 Fork Requirements: items 1-20 (chapter ) 1 Remove the temperature sensor, if installed. 2 Dismantle the heating band (3). 3 Remove the rods from the fork (6). 4 Screw out the nozzle head (4). 5 Pull out the shut-off needle (5). 6 Screw out the nozzle body (1). Chapter EP6GB0LA EP6DE0LA 0510WT

129 Design and function Risk of fire! Do not use flammable solvents! 7 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 8 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). 9 Mount the needle shut-off nozzle by completing the above steps in reverse order. 10 Screw in the nozzle body (1) by hand to the stop but do not tighten it. 11 Insert the shut-off needle (5). 12 Screw in the nozzle head (4) by hand to the stop but do not tighten it. 13 Mount the heating band (3) of the nozzle. 14 Screw in the temperature sensor by hand to the stop but do not tighten it. 15 Switch on the main switch. 16 Switch on the hydraulic system ( Hydraulic Start button). 17 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. EP6GB0LA EP6DE0LA 0510WT Chapter

130 Design and function Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 18 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor. Risk of injury from crushing during closing of the injection guard. Limbs might be crushed or caught between the injection guard and the nozzle plate! 19 Close the protective guard of the nozzle. Chapter EP6GB0LA EP6DE0LA 0510WT

131 Design and function ENG pneumatic needle shut-off nozzle with integrated control cylinder Nozzle body 2 Control cylinder 3 Rods 4 Nozzle head 5 Body 6 Clamping nut Requirements: items 1-20 (chapter ) 1 Remove the temperature sensor, if installed. 2 Dismantle the heating band. 3 Remove the rods (3). 4 Screw out the nozzle head (4). 5 Pull out the shut-off needle. 6 Screw out the nozzle body (1). EP6GB0LA EP6DE0LA 0510WT Chapter

132 Design and function Risk of fire! Do not use flammable solvents! 7 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush. Remove all grease residue from the grooves of the thread. Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components. The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles. Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifications! CAUTION Do not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated! 8 Lubrication of these parts results in contamination of the injection material. Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 C / 662 F) and neutral towards the material to be processed. Before installing, check the fi tting faces and the individual components for damage, wear and functioning. Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle). 9 Mount the needle shut-off nozzle by completing the above steps in reverse order. 10 Screw in the nozzle body (1) by hand to the stop but do not tighten it. 11 Insert the shut-off needle. 12 Screw in the nozzle head (4) by hand to the stop but do not tighten it. 13 Mount the heating band of the nozzle. 14 Screw in the temperature sensor by hand to the stop but do not tighten it. 15 Switch on the main switch. 16 Switch on the hydraulic system ( Hydraulic Start button). 17 Switch on the nozzle and screw barrel heating system and heat it to operating temperature. Chapter EP6GB0LA EP6DE0LA 0510WT

133 Design and function Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine! 18 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor. Tightening torques: Clamping nut (6) L Nm (443 ft lb) Nozzle head (4) L Nm (885 ft lb) L Nm (184 ft lb) L Nm (443 ft lb) Risk of injury from crushing during closing of the injection guard. Limbs might be crushed or caught between the injection guard and the nozzle plate! 19 Close the protective guard of the nozzle. EP6GB0LA EP6DE0LA 0510WT Chapter

134 Design and function Dismantling the screw barrel / screw Dismantling screw For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations! Never use machine components as climbing aids! When working at height, wear fall arrest gear! Use only tools and equipment that cannot cause damage to the components described below! Risk of injury and damage to components! Use only components (nozzle, screw, screw barrel, fixing screws) that have been supplied by Battenfeld or meet the Battenfeld specifications. For the tightening torques of the screws, see chapter Technical data, section 2.13 and the spare parts list. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! 1 Remove all residual material from the screw barrel by ejecting it. 2 Remove the paneling from the injection unit. Chapter EP6GB0LA EP6DE0LA 0510WT

135 Design and function 3 Detach the screw from the screw coupling. Loosen the 4 screws (1) of the screw coupling (2) and remove the 2 feather keys (3) Press the Setup mode button. EP6GB0LA EP6DE0LA 0510WT Chapter

136 Design and function 5 Press the button for injection piston movement and move the screw (4) to its forward position Press the button for injection piston movement and move the screw (4) to its back position. Remove the screw coupling (2). 4 Chapter EP6GB0LA EP6DE0LA 0510WT

137 Design and function 7 Insert the 2 lifting bolts (5). 5 8 Remove the 4 screws (6). 6 EP6GB0LA EP6DE0LA 0510WT Chapter

138 Design and function 9 Attach the screw barrel to the crane. 10 Ensure that the water hoses (7), the barrel heating cable (8) and the sensor of the traverse cooling (9) are not jammed or squeezed and lift the screw barrel Chapter EP6GB0LA EP6DE0LA 0510WT

139 Design and function CAUTION Ensure that the screw barrel is in a horizontal position when being lifted! The load capacity of the lifting gear and tackle must match the weight of the screw barrel! Do not use Nylon lifting tackle. The lifting tackle must be resistant to the temperature of the screw barrel! 11 Slowly lift the screw barrel with the crane. 12 Lift the screw barrel until the lower fi xing screws (10) of the fl ange can be inserted into the upper holes of the traverse (11). Insert the 2 fi xing screws (10) EP6GB0LA EP6DE0LA 0510WT Chapter

140 Design and function Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! 13 The screw (4) can now be pulled from the screw barrel When installing the screw in the barrel, ensure that the sealing ring (12) is correctly mounted Chapter EP6GB0LA EP6DE0LA 0510WT

141 Design and function Dismantling the screw barrel For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations! Never use machine components as climbing aids! When working at height, wear fall arrest gear! Use only tools and equipment that cannot cause damage to the components described below! Risk of injury and damage to components! Use only components (nozzle, screw, screw barrel, fixing screws) that have been supplied by Battenfeld or meet the Battenfeld specifications. For the tightening torques of the screws, see chapter Technical data, section 2.13 and the spare parts list. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! 1 Remove all residual material from the screw barrel, using a water jet. 2 Remove the paneling from the injection unit. 3 Unscrew guard plate (1) 1 EP6GB0LA EP6DE0LA 0510WT Chapter

142 Design and function 4 Disconnect the water hoses (2), the barrel heating cable (2), the sensor of the traverse cooling (4) and the sensor of the barrel heating (5) Chapter EP6GB0LA EP6DE0LA 0510WT

143 Design and function 5 Detach the screw from the screw coupling. Loosen the 4 screws (6) of the screw coupling (7) and remove the 2 feather keys (8) Press the Setup mode button. EP6GB0LA EP6DE0LA 0510WT Chapter

144 Design and function 7 Press the button for injection piston movement and move the screw (9) to its forward position Press the button for injection piston movement and move the screw (9) to its back position. Remove the screw coupling (7). 9 Chapter EP6GB0LA EP6DE0LA 0510WT

145 Design and function 9 Insert the 2 lifting bolts (10) Remove the 4 screws (11). 11 EP6GB0LA EP6DE0LA 0510WT Chapter

146 Design and function 11 Attach the screw barrel to the crane. CAUTION Ensure that the screw barrel is in a horizontal position when being lifted! The load capacity of the lifting gear and tackle must match the weight of the screw barrel! Do not use Nylon lifting tackle. The lifting tackle must be resistant to the temperature of the screw barrel! 12 Slowly lift the screw barrel with the crane. Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing! Chapter EP6GB0LA EP6DE0LA 0510WT

147 Design and function 13 The screw barrel can now be removed from the guide. EP6GB0LA EP6DE0LA 0510WT Chapter

148 6.2.8 Cleaning the screw barrel (change of injection material) Design and function To meet the ever more stringent quality requirement for plastic products, frequent and careful cleaning of all components that are in direct contact with the material is important Removal with high-grade polyethylene This method ensures that nearly all previously processed material is removed from the unit. The polyethylene itself must be pushed out of the screw unit by the new material. In most cases, there is no need for manual cleaning Material removal with cleaning granules The cleaning granules are normally made of a transparent, high-molecular thermoplastic material that becomes elastic but not fl uid at temperatures around 100 C (212 F). This material does not melt or attach itself to the equipment. It works like an elastic pusher, pushing all residual material from the previous batch from the screw barrel. In most cases, there is no need for manual cleaning. Prior to cleaning, remove the shut-off and the open nozzle and lower the nozzle temperature. The temperature of the screw barrel should be kept at below 300 C / 572 F), while the injection pressure is to to the lowest value. If required, it can be increased slightly during the process Cleaning the screw barrel CAUTION It is strictly forbidden to clean the screw with a gas burner, by sand blasting or by burning! These methods would have a negative effect on the mechanical and technological properties of the screw. Cleaning by such methods shall void all warranty cover. Clean the screw only with a brass brush. The use of a wire brush is prohibited, as it could damage the surface of the part. Also recommended is cleaning in a blasting system with duroplastic particles. The screw barrel is cleaned with a rotation brass brush attached to a rod. It can be operated by a power drill or similar tool Storage To store the cleaned screw and screw barrel, we recommend fi lling the barrel with little blue gel (approx. 200 g / 7 oz) or KC desiccant beads (from Kalichemie) and sealing all openings. The screws should be packed in plastic bags that also contain a little blue gel. This measure helps prevent corrosion during storage. Chapter EP6GB0LA EP6DE0LA 0510WT

149 Design and function 6.3 Hydraulic system General The hydraulic system of the injection moulding machine offers a number of advantages to the operator: Hydraulic system is easily accessible. Constant-displacement pump driven by an energy-effi cient server motor allows for smooth yet high-precision movements. The hydraulic components are installed in such a way that the lengths of pipe and hose lines is kept to a minimum. Easy to maintain Pump unit The full fl ow fi ltration ensure that the oil quality is kept at a high level for a long period of time. The pump unit consists of a servo motor, the pump carrier, the coupling and a constantdisplacement pump. A pressure oil line connects the pump unit with the pump block. The leak oil line and a suction oil line lead to the oil tank. There is no valve installed between the hydraulic tank and the pump unit Hydraulic tank The hydraulic tank is screwed into the machine frame and is equipped with a fi ller cap with oil fi ller screen, air fi lters, an electrically monitored oil level indictor and a temperature sensor. The hydraulic tank must only be fi lled through the oil fi ller screen of the fi ller cap. This opening is accessible in the machine frame near the front plate. The hydraulic oil must be pre-fi ltered in a mobile fi lter unit (fi lter size 3 μm, cleanliness class 17/15/12 according to ISO 4406, class 6 according to NAS 1638). The hydraulic tank is equipped with connections for an external oil fi lter unit. To clean the hydraulic tank, remove the tank cover. EP6GB0MA EP6DE0MA 0510WT Chapter 6.3-1

150 6.3.4 Return filter Design and function The return fi lter is equipped with a contamination sensor. if this sensor is triggered, an error message is displayed on the screen of the control unit. Change the fi lter cartridge (prod. no. MB628) at the next available opportunity (break in production run, e.g. at the end of a shift). If no fi lter cartridges are available in stock reorder them as soon as possible. As a rule, always change the fi lter cartridge each time the oil is changed. If it is necessary to change the oil prior to the next change interval (e.g. due to an error message or a negative oil analysis), also replace the fi lter cartridge. Utmost cleanliness is essential. The contamination sensor includes a cold start disabler, which means that the respective switch is disabled at oil temperatures below 27 C (80.6 F). Changing the filter cartridge Switch off the IMM and wait until the system is completely depressurised. IF THE HYDRAULIC SYSTEM IS NOT DEPRESSURISED PRIOR TO STARTING WORK ON THE UNIT, THERE IS A SERIOUS RISK OF INJURY AND DAMAGE TO THE EQUIPMENT AS IT MIGHT EXPLODE! RISK OF INJURY FROM BURNS! AT OIL TEMPERATURES ABOVE 60 C (140 F), WEAR SUITABLE PROTECTIVE CLOTHING! Unscrew the fi lter cap (3). Pull the fi lter cartridge (1) with the fi lter pot (4), holding it by the bracket. Remove the fi lter cartridge (1). Examine the surface for dirt particles. Such particles might indicate that components are damaged. Dispose of the fi lter cartridge (1). Before installing the fi lter cartridge, check it again to ensure that its designation corresponds to that of the removed fi lter cartridge. Chapter EP6GB0MA EP6DE0MA 0510WT

151 Design and function CAUTION Do not clean or re-use the filter cartridge! Remove the fi lter cartridge. The fi lter cartridge cannot be cleaned. Any attempt to clean the fi lter cartridge results in damage to the fi lter material, so that contaminations are not held back by the cartridge. Clean the inside of the fi lter pot (4) with a suitable agent (e.g. white spirit, petroleum), ensuring that no dirt is inadvertently moved to the clean side of the system. Examine the fi lter for mechanical damage, especially on the sealing faces and the threads. Replace damaged parts. Check the O-rings and replace damaged O-rings. CAUTION If damaged parts are not replaced and if the filter is not in proper working order, there is a risk of damage to other components of the system and impaired performance! Oil cooler (optional) In the oil cooler, cooling water is fed through pipelines inside the cooler, cooling down the hydraulic oil, so that the hydraulic oil can be kept at the required temperature by controlling the cooling water fl ow and temperature. Before connecting the oil cooler to the water circuit, ensure that the water quality meets the requirements specifi ed in chapter Maintenance. If the water does not meet these specifi cations, install a water fi lter (optional) to ensure that the cooling water stop valve works properly. This valve controls the water fl ow in the circuit and keeps the oil at a constant temperature. In units with closed cooling circuit (optional), the oil cooler is connected to the central heat exchanger, so that there should be no need for separate filtration Indicating and control device The oil temperature is measured inside the oil tank. The measured temperature is displayed on the screen of the machine control system. EP6GB0MA EP6DE0MA 0510WT Chapter 6.3-3

152 6.3.7 Pressure settings Design and function The hydraulic pressure for all functions is controlled by the servo drive based on the pressure settings entered on the screen in bar (psi) Speed settings The hydraulic speeds for all functions are controlled by the servo drive and entered on the screen in absolute values (mm/sec, inch/sec) Hydraulic core puller The hydraulic core puller (optional) consists of a base plate on which the necessary hydraulic valve are mounted and that contains all necessary consumer connections (DN 6). The hose lines and fi ttings for the connection of the core puller cylinder at the mould side are not included in the scope of delivery. Please note that the hydraulic pressure can reach 250 bar (3625 psi). All connecting elements must thus be rated for this pressure level! The hydraulic core pullers must be connected and commissioned by a specialist hydraulic technician! Always strictly adhere to the safety instructions in chapter Safety! Chapter EP6GB0MA EP6DE0MA 0510WT

153 Design and function 6.4 Pneumatic system UNIFEED material feed unit Application The UNIFEED material feed unit (optional) has been designed for use in conjunction with a plastics processing machine and is installed directly above the screw barrel, replacing the bulk hopper. It is particularly safe, as it contains no moving parts. The unit is also extremely easy and safe to use and service. The UNIFEED unit is the preferred feed option for the following materials: PE-HD, PE-LD, PS, PA, PA + GF, PP, ABS, POM, PPO. Design and function If the granule level in the container drops during metering to a level below the capacitive limit switch (6), the pneumatic valve (2) is opened. Compressed air is blown through the air nozzle (9) into the suction pipes (11), generating a vacuum, which extends into the suction chamber (11) and the container pipe (4). Due to the vacuum, a granule-air mixture is taken up through the suction lance (5) and the suction hose (1) into the container pipe (4). The granules are separated in a primary fi lter (8) from the suction air. Subsequently, the air is cleaned in a secondary fi lter (12) from dust particles and is released from the material feed unit. EP6GB0NA EP6DE0NB 0510WT Chapter 6.4-1

154 Design and function As the level of the material in the feed unit reaches the level of the capacitive limit switch, the air valve is switched off, shutting down the compressed air supply, and the fi lling process is terminated. At the end of the fi lling process, a small amount of compressed air is fed in pulses into the suction chamber (10), cleaning the primary fi lter from dust particles. Processing of regenerated granules In general, the UNIFEED material feed unit is suitable for the feeding of regenerated material in conjunction with new granule material. The grain size must not exceed 3 to 4 mm (0.12 to 0.16"). As regenerated material contains more dust particles, the fi lter becomes clogged up quicker, so that it must be cleaned at shorter intervals Pneumatic core puller CAUTION The pneumatic core puller (optional) consists of an electrically powered 5/2 pneumatic valve including all consumer connections made in plastic (DN 6 (0.24")). This functional module is mounted on the centre console or on the medium beam of the clamping plate. The equipment for the connection of the core puller cylinder at the mould side is not included in the scope of delivery. Please note that the device must be operated with dried compressed air and that the pneumatic pressure must not exceed 6 bar (87 psi). All connecting elements must thus be rated for this pressure level! Chapter EP6GB0NA EP6DE0NB 0510WT

155 Structure and function 6.5 Airmould The Airmould unit (option) enables the manufacture of high quality injection moulded articles with gas voids by gas injection. For this reason, the injection moulding machine, for example, may be operated with shorter cycle times and lower clamping forces. The defining feature of gas injection is the filling of the mould cavity with two fluids. One fluid is the polymer melt and the other is a gas, as a rule nitrogen (N2). Danger of death! Only use nitrogen (N 2 ) gas! It must be ensured that the plastic processed does not return aggressive or contaminating gases to the equipment. The gas may be injected either via the machine nozzle or through needles in the mould (injection modules). The "Airmould unit" is made up of a gas pressure control and a compressor unit. The main components of the gas pressure control are a pressure regulation module and an electronic control unit integrated into the IMM "Control unit". The pressure regulators (1) for regulation of the gas pressure in the machine nozzle or mould needles, are compactly built units and can thus be positioned very close to the gas injection point. Four pressure regulators can be controlled by one standard electrical control. HC4GB0OB HC4GB0OA 0510WT Chapter 6.5-1

156 Structure and function The main parts of the pressure generator (2) are a high pressure compressor, drive motor, gas bag, and accumulator bottles. A nitrogen generator can be arranged as a separate unit or integrated into the pressure generator, as the customer wishes. Chapter HC4GB0OB HC4GB0OA 0510WT

157 Structure and function 6.7 UNILOG B6 control General information UNILOG B6 is a new generation of control units which sets the standard regarding operator friendlinesss, speed and precision. The continuity of the Battenfeld philosophy and symbolism regarding operation is ensured by taking over the components from the previous control system - with an additional enlargement of the graphical user interface. A powerful system concept ideally adapted to the requirements of the hydraulic / sensor system promotes quick and precise movements of all machine axes. The precise analysis of all importent process variables provides the user with the control and supervision he needs for demanding tasks Control panel The control panel is divided into: 15"-TFT colour monitor with unrestricted touch-screen functions for operation and display 2 rows with soft keys to select the machine functions 48 membrane keys for operating the machine axes and the optional equipment Space for another 7 optional mechanical switches / keys 10 luminous ring membrane keys are available for the main machine functions (drive, heaters, operating modes). 2 USB interfaces can be used for the connection of data carriers (e.g. USB stick, printer, keyboard) or as an access system in combination with a password. More interfaces (2 USB and 2 Ethernet interfaces) are located at the rear side in the switch cabinet. HC6GB0QA HC6DE0QA 017WT1 Chapter 6.7-1

158 Structure and function Explanation of the picture Flexibility UNILOG B6 is a control concept which meets all demands concerning flexibility. With the free core puller programming, the user can, for example, quickly and flexibly set core puller sequences for different moulds. In standard operation, up to 8 core puller sequences can be parameterised with a large number of logical operations. Chapter HC6GB0QA HC6DE0QA 017WT1

159 Structure and function Holding pressure The combination of tabular input and graphic represenation facilitates the setting of the machine with the number of profile points being selected by ticking. A status bar on the extreme right of the screen will quickly inform you on the current machine status. Furthermore, two configurable status bars are available. By entering the machine settings in physical units and storing them on an USB stick, machine data records can be exchanged among machines of different size. HC6GB0QA HC6DE0QA 017WT1 Chapter 6.7-3

160 Structure and function Actual value graphics The most important means to assess the injection moulding process is the graphic representation of pressure and speed developments during the injection or holding pressure phase. The clear representation by the selection of curve numbers, different colours and the numerical representation of peak values and actual values within the change-over point enables a process analysis at a glance. Chapter HC6GB0QA HC6DE0QA 017WT1

161 Structure and function Cycle time analysis Analysis at a glance. The configurable cycle time analysis can be used for process optimisation and, at a glance, shows the effects in the value change cycle to individual movements and/or the total cycle. A complete overview is given by determining a reference cycle compared to the previous and the current cycle. HC6GB0QA HC6DE0QA 017WT1 Chapter 6.7-5

162 Structure and function Alarm system The production process can be backtraced by means of a comprehensive alarm / logging concept with different filtering possibilities. Reaction times in the event of plant failures are shortened by the automatic dispatch of messages Saving / Printing USB interfaces Data / printouts can be stored / sent to USB data carriers and/or USB printers compatible with WinXP TM by means of 2 USB interfaces located laterally on the operator panel and 2 other USB interfaces in the switch cabinet. Ethernet interfaces Two Ethernet interfaces with RJ45 connections are available in the machine switch cabinet for the integration in WAN/LAN networks, such as save / load machine data to / from a network server, or send print jobs to a network printer server, or for the purpose of remote diagnosis. Chapter HC6GB0QA HC6DE0QA 017WT1

163 Structure and function Control components System structure Overview of the Unilog B6 hardware structure Touch display unit and key unit Short-distance link connection (SDL) Automation PC Ethernet Powerlink connection (EPL) X2X Link connection X2X I/O system HC6GB0QA HC6DE0QA 017WT1 Chapter 6.7-7

164 Structure and function Touch display unit AP9xx The display unit is composed of two components: an automation panel device and an automation panel link plug-in module. These two components, plugged together, build the complete display unit. The resolution is 1024 x 768. Automation panel 900 Automation panel link plug-in module Cleaning: The display unit may be cleaned only while the device is switched off in order to avoid the release of unintended functions when touching the touch screen or pressing the keys or control devices. Use a moist cloth to clean the automation panel device. Only use water with a washing-up liquid, screen cleaner, or alcohol (ethanol) for moistening the cloth. Do not spray the cleaning agent directly on the automation panel device but spray it on the cloth! Under no circumstances use aggressive solvents, chemicals, scouring agents, compressed air, or steam jet. Clean the display with the touch screen at regular intervals. Chapter HC6GB0QA HC6DE0QA 017WT1

165 Structure and function Automation panel link plug-in module SDL The automation panel link plug-in module is the interface between an automation PC 620 and an automation panel 9xx. Graphic signals of an industrial PC (e.g. automation PC 260 monitor / panel output) are received, processed, and passed on to the automation panel 9xx. In the opposite direction, the touch screen, USB and SDL data, for example, are transferred to the respective interface of the industrial PC (e.g. automation PC 620). By means of simple slide-in technique, this plug-in module is plugged into the slide-in slot of the automation panel 900 and fixed to the automation panel by means of the two fixing screws (max. tightening torque 0.5 Nm). Fixing screws Display cable SDL cable 5CASDL.0xxx-00 Voltage supply +24 VDC In Panel IN (via SDL) This cable is necessary for the transmission of the graphic / touch screen / USB signals between display unit (automation panel link plug-in module) and automation PC. CAUTION The SDL cable may be connected and disconnected in the dead state only. Pin assignment Coat Coat HC6GB0QA HC6DE0QA 017WT1 Chapter 6.7-9

166 Structure and function Key unit 5E9000.xx Is used to operate the basic machine functions and special equipment. Due to the slide-in strip technique, it can be easily adapted to customer wishes. Voltage supply: +24 V DC Bus interface: 2 x Ethernet Powerlink (EPL) Chapter HC6GB0QA HC6DE0QA 017WT1

167 Structure and function Automation PC 620 The APC620 with Intel Pentium M processors and Intel 855GME chipset is available for applications with the highest demands in terms of processor performance. These processors, which were especially developped for mobile computing, offers many advantages for industrial use, too. High computer power is combined with low power input. The chip set includes an integrated graphics with optimised storage utilisation between system and graphics. The following individual components are absolutely necessary for operation: System unit. CPU board. Heat sink (depending on the CPU board). Main memory (depending on the CPU board). Drive (mass memory, such as Compact Flash card or hard disk) for the operating system. Software. PCI Slot 2 PCI Slot 1 Ap Link slot Add-On interface slot MIC, Line IN, Line OUT Monitor / panel SDL (Smart Display LinK) DVI Voltage supply +24 VDC USB1, USB2 Ethernet 2 Ethernet 1 COM2 COM1 Heat sink Heat sink seal Warning HC6GB0QA HC6DE0QA 017WT1 Chapter

168 Structure and function Battery: A lithium battery (3 V, 950 mah) buffers the internal real-time clock (RTC) as well as individually stored BIOS settings and is located under the black cover. The buffer duration of the battery is at least 4 years (at 50 C, 8.5 µa of the components to be supplied and a self-discharge of 40%). Lower slide-in slot 1 unlocking (1) LED for: Power, HDD, Link1, Link2 Slide-In Slot 1 Drive slot Add-On drive slot Compact Flash slot Power key Reset key Permanent magnet PS/2 keyboard or PS/2 mouse Battery Serial number label Hardware security key Lower slide-in slot 1 unlocking (1) (1) Before unlocking, the side cover of the Automation PC 620 must be closed Chapter HC6GB0QA HC6DE0QA 017WT1

169 Structure and function I/O modules Three basic elements form a single module: Bus module - electronic module - field terminal Easy installation - ingenious top-hat rail installation for optimum system handling 2 Stable triangle arrangement - direct connection between bus module and terminal block 3 Wide range of products - allows optimum adaptation for every task 4 Galvanically insulated - reliable operation under the toughest conditions 5 Diagnosis - on-site visual diagnosis, remote via software and electronic type plate 6 12x field terminal - ensures maximum packing density 7 Push-in terminals - no tools required for the handling of all standard connection cross sections 8 Coding - seamless works and customer coding HC6GB0QA HC6DE0QA 017WT1 Chapter

170 Structure and function X20BR9300 The X20 System is connected to the X2X Link with the bus receiver BR9300. The module is equipped with a feed for the X2X Link and the internal I/O supply. X20DI9371 The module DI9371 has 12 inputs in single conductor technology. The DI9371 is designed for sink input wiring. X20DO6322 The module DO6322 has six outputs in single or doubleconductor technology. The X20 standard terminal can be used 6x for continuous single conductor wiring. Double conductor wiring is possible with the 12x terminal. The DO6322 is designed for source output wiring. The nominal output current is 0.5 A. X20DO9322 The module DO9322 has 12 inputs in 1-conductor technology. The DO9322 is designed for source output wiring. The nominal output current is 0.5 A. X20DO8332 The module DO8322 has eight inputs in 1-conductor technology. The nominal output current is 2 A. The output supply is fed directly at the module. This means that no additional feed module is necessary. There is no connection from the module to the I/O supply potential on the bus module. X20AI4632 The module AI4632 has four inputs with 16-bit digital converter resolution. It can be switched between current and voltage signal (+/- 10 V DC) with the aid of different connection terminals. X20AO4632 The module AO4632 has four outputs with 16-bit digital converter resolution. It can be switched between current and voltage signal (+/- 10 V DC) with the aid of different connection terminals. Chapter HC6GB0QA HC6DE0QA 017WT1

171 Structure and function X20AT6402 The module AT6402 has six inputs for J, K, N and S thermocouple sensors. A terminal temperature compensation is integrated in the module. X20DC2395 The module DC2395 is a multifunctional counter module. It can be connected from an SSI sensor, an ABR sensor, two AB sensors or four event counters. Two outputs are available for pulse width modulation. The functions can also be combined. X20PS4951 The module PS4951 has four +/-10 V DC voltage supply channels for the potentiometer supply. HC6GB0QA HC6DE0QA 017WT1 Chapter

172 Structure and function Chapter HC6GB0QA HC6DE0QA 017WT1

173 Operation 7 Operation 7.1 General information For a number of reasons we would recommend commissioning of the IMM by Battenfeld personnel. This is not only for warranty reasons, but because at the same time: The machine can be checked for any transport damage or installation and connection faults. The operating personnel will be introduced to the IMM. Additional advice on operation, maintenance and repair can be given. Magnetic field hazard! In the immediate proximity of the magnetic fields of magnetic quick-action mould mounting systems (option), cardiac pacemakers, hearing aids, or disks etc. will be impaired! These magnetic fields will still be present after switching off the machine at the main switch. Only after demagnetising the magnetic modules will the magnetic fields be neutralised, i.e. the hazard will no longer be present. CAUTION The tiebar nuts may loosen due to the constantly changing loads. Therefore, the clamping plates of the tiebar nuts must be tightened and checked for security after the first 100 operating hours. CAUTION Every 2500 operating hours, the barrel heater bands must be checked for tightness at operating temperatures! Check the nitrogen pressure in the pressure vessel (option) at regular intervals as described in this chapter! HC6GB0RA HC6DE0RA 017WT1 Chapter 7-1

174 Operation 7.2 Initial start-up 1 Observe the operating manual and in particular the safety regulations in the "Safety" section. 2 Unload, transport, install and level the machine as described in the "Transport - Installation" section. 3 Prepare the hydraulic system as described in the chapter "Transport - Installation". 4 Prepare the water system as described in the "Transport - Installation" section. 5 Turn on water supply to oil cooler 6 Prepare the pneumatic system as described in the "Transport - Installation" chapter 7 Open the air supply from the compressed air system to the air supply unit (option), UNIFEED material feeder (option), mechanical scotch (option) 8 Prepare the electrical equipment as described in the chapter "Transport - Installation". 9 Switch on the supply voltage (low voltage distribution). 10 Ensure that there are no highly combustible and explosive air mixtures near the screw barrel heating 11 Ensure that no easily combustible materials, e.g. styrofoam, rags etc., or explosive air mixtures are near the inlets of the radial fans (option). 12 Lubricate lubrication points, as described in the "Transport - Installation" chapter The oil level must be checked before the first start-up and, if necessary, oil must be filled in or refilled in the "Axial bearing" of injection unit 8800 and if the servo-motor option is installed. 13 Prepare the Airmould unit (option) as described in the "Airmould" chapter. For the preparation of a mobile Airmould unit (option) please refer to the separate operating manual. 14 Switch on drive ("Drive On" key). The standard machine has an oil preheating system, and can not be run until a hydraulic oil s operating temperature has been reached (after about 15 min.). 15 Clear any error messages which appear (see "UNILOG B6 User s Manual", "List of all alarm messages" section). 16 Mount the mould as described in the "Transport - Installation" chapter and adjust the clamping force and the mould mounting height. 17 Connect the peripheral equipment (option) as described in the "Transport - Installation" chapter 18 Check the safety device as described in the "Transport - Installation" chapter Chapter 7-2 HC6GB0RA HC6DE0RA 017WT1

175 Operation 19 Open and close the safety gate and purge guard (to test the safety gate monitoring circuit) It is forbidden to stand on the machine or to reach into the injection unit during operation! 20 Carry out the test run and interlock test as described in the "Transport - Installation" chapter 21 Carry out the test run without / with material as described in the present section. 22 Select the operating mode and start the machine. 7.3 Starting the machine after EMERGENCY STOP The emergency stop button is a safety switch for shutting the machine down quickly in the case of danger. If it has been operated, it must be released after the fault or the cause of the external emergency stop (periphery, e.g. the robot) has been cleared, by turning it in the direction of the arrow. Then the machine is switched on again as described in the paragraph "Operation", and if necessary, the mould cleared of the moulding by means of the ejector. The starting position of the machine is: Mould fully open, ejector, nozzle and screw back, core puller (option) out. 7.4 Checking the nitrogen pressure Check the nitrogen pressure in the pressure vessel (option) before and during operation. In case the nitrogen pressure falls short of the indicated value (see name plate), nitrogen has to be refilled. The safety regulations in the chapter "Safety" are to be followed without fail! Work at pressure vessels may only be carried out by specially trained personnel! Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released! Risk of explosion! Only use nitrogen "N2" as gas! For instructions on how to refill, reduce and check the nitrogen pressure, please refer to the "Transport - Installation" chapter. 1 Check at least once within the first 40 operating hours. Major losses in nitrogen will immediately be detected and be compensated. 2 In case no losses have been detected during the first inspection, the next inspection is to be carried out after 500 operating hours. 3 After this inspection further inspections may be carried out at an interval of 1000 operating hours. HC6GB0RA HC6DE0RA 017WT1 Chapter 7-3

176 Operation 7.5 Test run without material After commissioning or changing the mould, the movements of the various units should be tested before running a few manual cycles with a mould mounted. The safety regulations in the chapter "Safety" are to be followed without fail! 1 Check whether the switch cabinet, safety guards and safety gates have been properly installed or closed. 2 Clear inside of the machine of all foreign bodies (forgotten mould). 3 Switch on the supply voltage (low voltage distribution) - commissioning only. 4 Switch on main switch. 5 Release the emergency stop button(s) on the machine by rotating a quarter of a turn clockwise. 6 Open the water supply from the cooling system to the individual users (oil cooler, cooling water flow governor, etc.) - commissioning only 7 Open the air supply from the compressed air system to the air supply unit (option), UNIFEED material feeder (option), mechanical scotch (option) -commissioning only 8 Check the safety device as described in the "Transport - Installation" chapter 9 Open and close all safety gates once (to test the safety gate monitoring). Press the "Open safety gate" and "Close safety gate" keys in case of a power-operated safety gate (option). 10 Switch on drive ("Drive On" key). This action also starts the oil preheating. Now, you have to wait until the hydraulic oil is heated up to a minimum of 40 C (104 F) Start the pump without load and run it for a few seconds to allow for adequate lubrication. 11 Switch on bypass filtration unit (option). Chapter 7-4 HC6GB0RA HC6DE0RA 017WT1

177 Operation Before operating the machine the safety regulations in the operating manual(s) of any peripheral equipment must be followed without fail! 12 Commission peripheral equipment (option) according to the operating manuals and set them to the starting position, i.e. the position in which no damage to the devices or to machine components is possible. 13 Clear any error messages which appear (see "UNILOG B6 User s Manual", "List of all alarm messages" chapter). 14 Press the "Manual operation" key. 15 Log on to the control. An activation of the key symbol opens the window for "System password". For the log on to the control refer to chapter A 7 in the control unit s manual. 16 Setting the set values (see B6 user manual) The set values for "Injection" are to be set as low as possible for a respectable injection cycle. Otherwise the mould can possibly be overpacked. When opening the mould and using magnetic quick-action mould mounting systems (option) in particular the chucking power can be exceeded. For moulds with a smaller base the ejector force may exceed the retention force of the clamping elements which will cause the mould to disengage. During operation "without material" it is necessary that no shot volume is entered, thus the set value is 0. In this, case the screw is only to be retracted by means of decompression in order to avoid the injection of material. Set the set values for "Injection", "Locking force" and "Ejector" as low as possible for an acceptable injection cycle. Otherwise forces may be present when opening the mould which can possibly exceed the limit range of the clamping elements! HC6GB0RA HC6DE0RA 017WT1 Chapter 7-5

178 Operation Fire hazard! No smoking! Make sure that there are no flammable liquids, open flame, etc. near the screw barrel heating or barrel cooling (option)! No drawn-in material or explosive air mixtures may be near the inlet area of the radial fans to the barrel cooling (option)! 17 Remove all materials, liquids and objects which should not be near the injection unit. 18 Press "Heating on" key (switch on barrel heating). (see B6 user manual) 19 Bring the machine to the following starting position: Mould open Ejector fully back Nozzle back Screw back 1 Core puller out (option) Chapter 7-6 HC6GB0RA HC6DE0RA 017WT1

179 Operation 20 Press "Automatic mode" key. Operating and other personnel may only stand in front of the machine on the operator s side during operation! 21 Press "Mould close" key; an automatic cycle is started. The "Semiautomatic" modes can be started by closing the safety gate (option). In case of power-operated safety gates at the clamping unit, these gates will be opened automatically at the end of the cycle in the "Semiautomatic" operating mode. During the test run, listen for any unusual noises and check the function of the safety gates. The "Fully automatic" and "Semiautomatic" modes are interrupted by pressing the "Manual mode" key or an emergency stop button. Any leaks which arise in the first few operating hours can usually be cured simply by tightening the screw connections. 22 The "Automatic" operating mode can be stopped at the end of the cycle by pressing the "Open mould" key during the cycle. In this case, the error message "manual end of production initiated" is displayed. After the cycle has been interrupted, further operation can be initiated by pressing the "Close mould" key. HC6GB0RA HC6DE0RA 017WT1 Chapter 7-7

180 Operation 7.6 Filling the material hopper 1 Make sure that the main switch is switched off and secured against unauthorised reconnection. Surfaces marked with the "No step symbol must not be stood on! If the material hopper, the material feeder or the stuffing device are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for filling! 2 Move the climbing aid in front of the machine. 3 Clean the material hopper and check for foreign particles. For this reason the use of open material bags should be avoided. Follow the plastic manufacturers instructions! When processing plastics which give rise to harmful gases dusts or vapours, the proprietor of the machine has a duty to provide suitable extraction for the protection of operating personnel! CAUTION The operator has a duty to ensure no foreign bodies enter the material hopper of barrel throat! 4 Swing material hopper to mid position 5 Fill in material 6 Swing material hopper above the feed throat of the screw barrel 7 Remove climbing aid from the working area of the machine. Chapter 7-8 HC6GB0RA HC6DE0RA 017WT1

181 Operation 7.7 Test run with material The safety regulations in the chapter "Safety" are to be followed without fail! 1 Prepare the machine as described in chapter "Test run without material", steps 1 to 3. 2 Fill material as described in section "Filling the material hopper". 3 Prepare the machine as described in chapter "Test run without material", steps 4 to Preselect the metering profile (shot volume) correspondingly. 5 Check the safety device as described in the "Transport - Installation" chapter 6 Open mould; move ejector and nozzle back; move core puller back, if necessary 7 Drive screw forward ("Injection" key) 8 Press "Metering" key and carry out a manual metering process. HC6GB0RA HC6DE0RA 017WT1 Chapter 7-9

182 Operation 9 Select the desired program "Automatic or "Semiautomatic Depending on the program selection either press the "Close mould" key or close the safety gate (see step 22 in the "Test run without material" section) to start the machine. In this way several cycles are run. The movements of the various units, the settings and the quality of the mouldings are now to be checked. Depending on the application, appropriate corrections are made to the various set values in order to achieve the quality required for the moulding. Once all the set values have been entered, they can be saved to avoid unnecessary data loss. For additional security the set values complete with mould number and part number should be printed out and placed in the Operating Manual. For procedure see the UNILOG B6 User manual, chapter 25 "Data records". 10 Log off from the control CAUTION To prevent set value entries by unauthorised persons, the user must log off after finishing setting! 10.1 An activation of the key symbol opens the window for "System password". If you want to interrupt or finish your work at the control unit, you will have to logout first. This procedure prevents unauthorised input at the control unit Select the "Logout" key. If the logout is successful, the window is automatically closed. As an acknowledgement, user level 90 is displayed in the "User level symbol". Chapter 7-10 HC6GB0RA HC6DE0RA 017WT1

183 Operation 7.8 Operation The operation of the machine does not differ from the procedure described in paragraph "Test run with material" and the procedures described in this section. After each shutdown and before each start-up of the machine, the safety devices have to be checked after switching on the main switch as described in the "Transport - Installation" chapter! The safety regulations in the chapter "Safety" are to be followed without fail! For the first few hours in which the machine is used under production conditions, the following should be monitored in particular: 1 The hydraulic oil temperature. The optimum working temperature of the hydraulic oil is between 45 C and 50 C (113 F and 122 F). The current oil temperature will be displayed on the "Hydraulics" screen page. 2 The proper fit of the tiebar nuts. The tiebar nuts may loosen due to the constantly changing loads. Therefore, the clamping plates of the tiebar nuts must be tightened and checked for security after the first 100 operating hours. 3 The screw barrel heater bands The barrel heater bands must be checked every 2500 operating hours for security at operating temperatures. 4 The nitrogen pressure within the pressure vessel (option); see "Checking the nitrogen pressure" chapter. Periodical checks should be performed during operation at regular intervals and according to the procedure described in the "Maintenance" chapter. Visible defects are to be remedied immediately. Remedy damage immediately. Hydraulic oils escaping at high pressure can cause severe injuries and fires! This applies especially to hydraulic fittings and hose assemblies. HC6GB0RA HC6DE0RA 017WT1 Chapter 7-11

184 Operation 7.9 Shutting down the machine 1 Press the "Manual operation" key. 2 Set peripheral equipment (option) to the starting position and switch off any peripheral equipment according to its operating manual. 3 Switch off the "UNIFEED" material feeder (option). 4 Pull the hopper away from the feed throat of the barrel 5 Move the core pullers out of the mould if appropriate. 6 Move the clamping platen to the starting position (Mould open). If necessary remove the moulding(s) from the mould using the ejector Burns hazard! Do not touch escaping material! 7 Swing the material hopper from the inlet area of the screw barrel to the centre position 8 Press the "Injection unit back" key. 9 Place an appropriate reservoir in front of the nozzle and purge the remaining material at short intervals. 11 Switch off drive ("Drive off" key). 12 Switch off the heater ("Heater off" key) 13 Close and relief the cooling water supply (add antifreezing agent, if necessary) from pressure 14 Close and relieve the compressed air system (option) from pressure 15 Switch off the main switch and use a padlock to prevent accidental reconnection. The main switch should be operated whenever possible without applied load. Chapter 7-12 HC6GB0RA HC6DE0RA 017WT1

185 Operation 7.10 Extended shutdown 1 Shut down the machine as described in "Shutting the machine down. Swing the material hopper to the emptying position and fill the remaining material into an appropriate container. 2 First free the screw barrel and the screw from the remaining melt and purge out with polyethylene. 3 Depending on the material to be processed, the nozzle and the screw must be removed and cleaned. 4 Preserve the cavities of the mould according to the manufacturer s instructions. 5 For a hydraulic system with integrated pressure accumulator (option) deflate the nitrogen as described in section "Transport - Installation". 6 Treat all bare parts with a anticorrosive agent. 7 Empty the cooling water system, blow out with compressed air and treat with anticorrosive agent HC6GB0RA HC6DE0RA 017WT1 Chapter 7-13

186 Operation 7.11 Shut down procedure 1 Shut down the machine as described in "Shutting the machine down, steps 1 to 10 2 Preserve the cavities of the mould according to the manufacturer s instructions Dismantling the mould In this paragraph the dismantling of a mould fastened with mould clamps is described. The dismantling of a mould fastened with a quick-action mould mounting system basically corresponds to the following description. The only differences will be in the Remove mould of the clamping platen / nozzle platen paragraphs. To this end use the appropriate control elements at the operator panel. See also paragraph "Mould mounting using quick-action mould mounting systems" in the "Transport -Installation" chapter 1 Press the "Mould Close" key and close the mould. The mould may only be dismantled by an authorised skilled technician! 2 Disconnect the ejector coupling (mould to hydraulic ejector cylinder). Burning hazard if touched! At mould temperatures above 60 C (60,00 C) wear appropriate PPE! 3.3 Let the mould cool down to a safe temperature (material dependent). 3.4 Prepare the mould for dismantling (Disconnect cooling hoses, heating cables etc.). Chapter 7-14 HC6GB0RA HC6DE0RA 017WT1

187 Operation 5 Mount the safety strap holding the two mould halves together. The safe working load of the lifting equipment must equal or exceed the weight of the mould! 6 Mount the lifting gear at the mould. 7 Slightly tension the lifting gear. 8 Press the "Setting" key. 9 Loosen the mounting elements of the mould on the clamping platen. 10 Move the clamping platen back. 11 Loosen the mounting elements of the mould on the nozzle platen. 12 Remove them from the centering hole in the nozzle platen. HC6GB0RA HC6DE0RA 017WT1 Chapter 7-15

188 Operation Danger of death! It must be ensured that no persons stand or linger under the suspended load! 13 Lift the mould horizontally out of the opened clamping unit. 14 Protect the mould according to the mouldmaker s instructions and prepare it for storage Further measures for shutting down 1 Let the heating elements and their guardings, temperature control units and their flow and return lines and their couplings and mounting elements cool down to a safe temperature. 2 Move the piston rods of the hydraulic cylinders in the setting mode as far as possible into the hydraulic cylinder to protect them from corrosion. In case of a possible disassembly, release any remaining pressure by carefully loosening (but not completely undoing) the appropriate hydraulic screw connection. If the place of installation is to be changed, the clamping and the injection unit has to be moved to the transport position as described in "Changing the place of installation". 3 Press "Drive stop" key. 4 Turn off the main switch and use a padlock to prevent accidental reconnection. Cleaning materials are classed as flammable liquids, hazardous to health. The manufacturer s instructions are to be followed without fail! 5 Dismantle nozzle (and nozzle head) as well as screw and screw barrel and clean them. Chapter 7-16 HC6GB0RA HC6DE0RA 017WT1

189 Operation Emptying the hydraulic system Work at the hydraulic system may only be carried out by a skilled hydraulic technician! 1 For a hydraulic system with integrated pressure accumulator (option) deflate the nitrogen as described in section "Transport - Installation". Burning hazard if touched! At oil temperatures above 50 C (50,00 C) wear appropriate PPE! Avoid any skin contact! If hydraulic oil gets into the eyes, rinse carefully with water and consult a physician! 2 Clean the area round the venting filter. 3 Thoroughly clean the area around the filler and screw plugs on the transport and storage containers. 4 Unscrew the venting filter lock and remove the complete venting filter from the pipe socket. Fire hazard! No smoking! Make sure that there are no flammable liquids, open flame, etc. nearby! Environmental hazard! In case of leaking hydraulic oil follow the legal provisions and regulations without fail! 5 Empty the hydraulic tank by means of a pump unit via the pipe socket. The suction hose must reach to the bottom of the hydraulic tank. The pump unit must be permissible for hydraulic systems. The tank must be approved in accordance with the applicable laws and regulations and must be dimensioned to be able to hold the hydraulic oil volume (see "Technical Data" section). HC6GB0RA HC6DE0RA 017WT1 Chapter 7-17

190 Operation 6 Place the venting filter on the pipe socket again. 7 Remove the tank cover and clean the hydraulic tank 8 Remove the housing of the hydraulic filter. Dispose of the liquid in a suitable container, see chapter "Maintenance", "Hydraulic filter" paragraph. When storing and disposing of hydraulic oils and used oil the local laws and regulations are to be followed without fail. The proprietor of the machine is responsible for proper waste disposal! When disposing of the oil pan and cloths drenched with hydraulic oil the laws and regulations applicable must be followed without fail. The proprietor of the machine is responsible for proper waste disposal! Chapter 7-18 HC6GB0RA HC6DE0RA 017WT1

191 Operation Emptying the cooling water supply If the cooling system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! Burning hazard if touched! At water temperatures above 50 C (50,00 C) wear appropriate PPE! 1 Cut off the water supply to the oil cooler Cut off the water supply (1) to the cooling water flow control. 3 Turn the two hand-wheels (2+3) of the cooling water flow control counterclockwise (Close cooling water flow). 4 Disconnect the cooling water supply and return lines from the oil cooler 5 Drain the cooling water from the supply and return lines of the oil cooler to appropriate systems or containers 6 Disconnect the cooling water return (4) from the cooling water flow control and drain the cooling water to appropriate systems or containers. 7 Disconnect the cooling water flow (1) from the cooling water flow control and drain the cooling water to appropriate systems or containers. 8 Turn both hand-wheels (2+3) of the cooling water flow control cw (Open cooling water flow) and drain the cooling water to appropriate systems or containers 9 Disconnect the cooling water flow and return (5+6) of the users and drain the cooling water to appropriate systems or containers 10 Connect the compressed air hose to the supply lines of the oil cooler and the cooling water flow control and blow out with compressed air. 11 Drain the remaining cooling water from the supply and return lines to appropriate systems or containers 12 Insert plugs into the fittings of the supply and return lines to protect them against contamination HC6GB0RA HC6DE0RA 017WT1 Chapter 7-19

192 Operation Evacuating the compressed air system If the compressed air system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! 1 Cut off the compressed air supply to the air supply unit Turn the pressure control valve setting knob (1) counterclockwise until the pressure gauge (2) has dropped to 0 bar. 3 Turn venting screw (3) counterclockwise. 4 Turn condensate drain screw (3) counterclockwise; drain condensate to a suitable container; turn condensate drain screw clockwise Other measures 1 Follow the procedures in the respective operating manuals without fail before shutting down the peripheral equipment. 2 All bare and unplated moving parts and guides (tiebars, piston rods, etc.), and all unpainted, unplated bolts must be preserved using an oily rust preventing agent. Chapter 7-20 HC6GB0RA HC6DE0RA 017WT1

193 Operation Disconnecting the electric system The machine may only be disconnected from the power supply by a skilled electrician. The safety regulations in the chapter "Safety" are to be followed without fail! 1 Switch off the supply voltage (low voltage distribution) to the machine. 2 Disconnect the supply lines in the switch cabinet from the mains and the heating power terminals. 3 Secure the supply lines against interference according to locally applicable regulations. 4 Place desiccant medium for protection of connecting terminals, relays, etc. from corrosion into the electrical cabinet Measures after an extended shutdown 1 Clean the machine from dust and rust preventing agent, see chapter "Transport - Installation". 2 Note the service life of the hydraulic hoses and hose assemblies, see chapter "Maintenance". 3 To prevent the hydraulic pump(s) from being damaged, check whether they are filled with hydraulic oil; see chapter "Transport - Installation". 4 Replace the "Hydraulic filter" and "Venting filter" filter elements; see chapter "Maintenance". The isolation value may only be checked and moist windings may only be dried by a qualified electrician. The safety regulations in the chapter "Safety" are to be followed without fail! 5 Check the insulation values of the hydraulic motors windings. 6 Observe the service life of the battery in the control unit; see chapter "Maintenance". 7 Prepare the machine according to section "Transport - Installation". 8 Proceed in the same order as described in "Test run without material" to "Test run with material" HC6GB0RA HC6DE0RA 017WT1 Chapter 7-21

194 Operation 9 Maintain hydraulic system After extended shutdown, in particular, if there are extreme climatic conditions, the movement of some hydraulic components (e.g. valves) may be restricted due to gumming or precipitations within the hydraulic oil. For this reason the machine should be carefully restarted at low set values for the movement speeds and pressures. Carefully observe whether all hydraulic functions have been carried out and the proper function of the machine is ensured. If necessary, the machine should be filled and flushed out with a cleaning oil (HLPD according to DIN Part 2, Class ISO VG 32). These are hydraulic oils with cleaning additives (identifying letter "D" = "detergents"). After successful flushing, the machine should be refilled and used with the standard hydraulic oil (HLP 46). 10 Follow the procedures in the respective operating manuals without fail before restarting the peripheral equipment. Chapter 7-22 HC6GB0RA HC6DE0RA 017WT1

195 Operation 7.13 Changing the place of installation 1 Prepare the machine as described in "Shut down procedure". 2 Move the injection unit to its foremost position (into the nozzle platen) before changing the place of installation 3 Move the clamping platen to the "Mould open" position and adjust the maximum mould mounting height. 4 Open the clamping unit s safety gates on the operator s side and the rear and secure by a rope, around the machine frame tied to each handle. 5 Remove foundation bolts if necessary. 6 If the machine is to be moved to an external installation site, lift it using the appropriate lifting equipment, see chapter "Transport - Installation" and dismantle the levelling mounts. 7 Attach lifting equipment as described in paragraph "Transporting the machine" in chapter "Transport - Installation". 8 Transport the machine using the appropriate means of transportation (fork lifting truck, crane) as described in chapter "Transport - Installation" 9 If the machine is to be moved to an external installation site, secure the IMM with ropes suitable for the weight of the machine on the means of transportation (e.g. truck) The complete machine may only be placed on a level surface capable of supporting the appropriate load. 10 Unload, install, level and commission the machine at the new installation site as described in chapter "Transport - Installation" HC6GB0RA HC6DE0RA 017WT1 Chapter 7-23

196 Operation 7.14 Disposal The proprietor is obliged to dispose of all components, lubricants, hydraulic and gear oil as well as other aids (cleaning cloths, cleaning agents, etc.) according national and international laws and regulations. This applies especially to those components which have been in contact with products hazardous to the environment (lubricants, hydraulic and gear oils). Please contact the responsible authorities before disposal. You will receive detailed information on laws and regulations applicable, the facilities for disposal as well as on authorised waste disposal companies. Ask your lubricant supplier for the safety data sheets according to DIN for the products they supply you with. Among others, these contain information on waste disposal. If possible, the materials and substances should be recycled. The provisions on waste disposal within the European Union (EU) can be found in the "Europäischen Abfallkatlogverordnung" (EAKV) ("European Waste Disposal Catalogue Regulation"). This regulation is to translate the provisions of the decision 94/3/EC on a waste disposal directory according to Article 1, section a of the Directive of the Council 75/442/EEC on wastes into the German legislation. In the Directive of the Council 75/442/EEC measures on the avoidance, recycling and the disposal of wastes are described in Article 3; Article 4 contains the compliance with the principle of non-hazardous waste recycling and disposal. Article 5 stipulates the principles of the nearest possible and self-reliant waste disposal. Chapter 7-24 HC6GB0RA HC6DE0RA 017WT1

197 Maintenance 8 Maintenance 8.1 General Careful installation and proper care are indispensable to ensure the reliable function of the injection moulding machine. Daily visual inspections help prevent downtimes. Carry out regular inspections and maintenance and replace worn parts. Only use parts of the same quality (strength, material properties) and design as the original parts. Malfunctions and faults caused by inadequate or improper maintenance can lead to high repair costs and long downtimes of the machine. Regular maintenance is therefore imperative. If you have any queries regarding the servicing or maintenance of the machine, please contact our technical customer service or one of our agents. For addresses, see chapter Customer service. Always strictly adhere to the safety instructions in chapter Safety! Before carrying out any maintenance tasks, shut down the machine at the main switch and secure it against inadvertent switching on! 8.2 Transport, storage and disposal of lubricants Lubricants and hydraulic fluids are hazardous substances that can cause damage to the environment. Therefore strictly observe the application statutory regulations for the handling and disposal of such substances, including the regulations in the water protection, construction, waste disposal, transport, processing and occupational safety regulations. These regulations cover all issues in connection with the transport, storage and disposal of these substances. However, even strict compliance with these regulations cannot fully eliminate the risk of accidents with lubricants. In the event of such an incident, immediately notify the relevant authorities (environmental protection / police / fi re brigade). The duty of notifi cation of the authorities depends on the amount of spilt lubricant. The operator must take preventive measures to prevent oil spillage. Such measures include for example an oil incident plan, the storage of suffi cient quantities of oil-binding agents, regular checks of the seals of the sewage inlets and the provision of suitable tools and equipment to prevent the the oil from reaching critical areas. EP6GB0SA EP6DE0SA 0510WT Chapter 8-1

198 Maintenance Request the relevant material safety data sheets according to DIN from your oil supplier. They contain information on the product, including: Chemical composition and physical properties Protective measures, storage and handling instructions Measures to be taken in the event of accidents and fi re 8.3 Disposal of electrical and electronic components Dispose of all electrical and electronic components according to the statutory regulations. 8.4 Hydraulic fluid and lubricant table CAUTION The test run of the machine at the factory is always carried out with oil containing zinc. IT is however possible to operate the machine with an equivalent zinc-free oil. The residual quantity of oil in the system upon delivery is approx. 5%, and there are no concerns on the part of the oil supplier as regards mixing with the new oil. This list is based on the recommendations made to us by the mineral oil companies. It is however possible to use equivalent products from other suppliers, provided that their specifi cations match those of the products listed here. Chapter 8-2 EP6GB0SA EP6DE0SA 0510WT

199 Maintenance Only only pre-fi ltered hydraulic fl uid of cleanliness class 17/15/12 according to ISO 4406! Lubrication point Hydraulic equipment*) Gearbox, axial bearing and oil lubrication Central oil lubrication Central lubrication grease and grease Three-phase motor & electric motors**) Pneumatics & electromagnetic coupling Designation to DIN HLP 46 DIN T2 CLP 220 DIN T3 CG 220 DIN T3 K 2/3 R - 40 DIN HLO 10 / CL 10 DIN T1 Agip OSO 46 Agip Blasia 220 Agip ASP 220 Agip Exidia Agip ACER 10 Aral Vitam GF 46 Aral Degol BG 220 Aral Deganit B220 - Aral Vitam DE 10 AVIA FLUID RSL 46 AVIA GEAR RSX 220 Slideway oil RSU AVIA FLUID RL 10-C BP Energol HLP-HM 46 BP Energol GR-XP 220 BP Maccurat 220 D - BP Energol HLP-HM 10 Castrol Hyspin AWS 46 Castrol Alpha SP 220 Magnaglide D 220 SLX Grease Castrol Hyspin AWS 10 NUTO H 45 SPARTAN EP219 FEBIS K SPINESSO 9 HYDRAN TS 46 GIRAN 220 HYDRAN G220 Pluton EM CIRKAN 10 Mobil DTE 25 Mobilgear 630 Mobil Vactra Oil No. 4 - Mobil Velocite Oil No. 6 RENOLIN B 15 VG 46 RENOLIN CLP 220/220 Plus RENEP CGLP RENOLIN B 3 VG 10 Q8 Haydn 46 Q8 Goya 220 Q8 Wagner Q8 Haydn 10 Shell Tellus 46 Shell Omala 220 Shell Tonna S 220 Aero Shell Grease 16 Shell Morlina Straburags NBU8EP *) Hydraulic fl uid: Use only fl uid of cleanliness class 15/12 according to ISO 4406 after prefi ltration! **) Air-cooled three-phase motors only EP6GB0SA EP6DE0SA 0510WT Chapter 8-3

200 Maintenance 8.5 Maintenance schedule Every 8 operating hours Check that all safety devices (1) and all safety covers (2) and guards (including mechanical closing guard) are properly mounted. Visually inspect the machine for damage. Replace defective indicator lamps (3) without delay. Check that the switch cabinet door (4) is kept closed at all times. Check the switch cabinet for dirt and clean it, if necessary. Chapter 8-4 EP6GB0SA EP6DE0SA 0510WT

201 Maintenance Every 160 operating hours Check the fi lter pad(s) of the fan in the switch cabinet and the machine frame for contamination. Check all hydraulic fi ttings, hose lines, cylinders, valves, pumps, etc for leakage or damage. Check the air-conditioning devices (condensate tank, fi lter), if installed. Check the fi lling level of the central lubrication pump (STRABURAG NBU 8 EP) (1) and the oil lubrication pump (2). 2 1 Check the various spindles (injection side, clamping side) for oil fi lm. The spindles must be covered around their outer diameters and along the coupling races with a thin fi lm of lubricant! Spindle at injection side Spindle at clamping side Check the grease (3) and oil lubrication lines (4) for damage and proper fi lling with lubricant. 4 3 Filling level EP6GB0SA EP6DE0SA 0510WT Chapter 8-5

202 Maintenance Check the oil level in the hydraulic tank (5), the injection drive and the metering drive (6). Check the metering and injection drives for leakage and damaged shaft seals. 5 6 Chapter 8-6 EP6GB0SA EP6DE0SA 0510WT

203 Maintenance Every 500 operating hours Treat all bare metal parts (beams (1), piston rods (1)), that are not moving along other components with a corrosion protection spray. CAUTION: Do not spray the crosshead guide (3) Apply grease to the grease lubrication points of the clamping plate support (4), the drive guide at the injection side (6) and the injection side guide (7) (linear guide) EP6GB0SA EP6DE0SA 0510WT Chapter 8-7

204 Maintenance Remove escaping grease. CAUTION: Do not lubricate the scraper of the thread roller screw drives (8). Complete a functional check of the stop bar of the mechanical closing guard (optional). Clean the fi lter cartridge of the air purifi er unit (optional). Check the leakage bottle for the toggle lever oil in the machine frame and empty it, if necessary! 8 9 Chapter 8-8 EP6GB0SA EP6DE0SA 0510WT

205 Maintenance Every 2500 operating hours Check whether the operating manual is in place and complete. Check the heating bands for correct position and proper fi t. 1 Retighten all terminals in the switch cabinet. Check all cables for damage. Replace the fi lter pad(s) of the fans in the switch cabinet and the machine frame. Clean the switch cabinet. Test the emergency-stop circuit. EP6GB0SA EP6DE0SA 0510WT Chapter 8-9

206 Maintenance Check the screw coupling (2) and tighten the screws, if necessary. 2 Lubricate the grease lubrication points of the height adjusting unit (3) Chapter 8-10 EP6GB0SA EP6DE0SA 0510WT

207 Maintenance Every 5000 operating hours Check the stroke transducer for the ejector (1) and the ejector for the nozzle movement (2) for dirt. 1 2 Visually inspect the electrical components. Check the nozzle for wear and proper centring. Test the hydraulic oil quality (change oil, if necessary). To determine the local operating conditions to adjust the change interval, test the hydraulic oil at shorter intervals (e.g. monthly) during the initial operating phase. EP6GB0SA EP6DE0SA 0510WT Chapter 8-11

208 Maintenance Change the fi lter cartridge of the hydraulic fi lter (3). 3 Check all screw connections and fi ttings for proper tightness and retighten, if necessary. Check the insulation resistance and the protective conductor system. Lubricate the axial bearing of the clamping motor (4) with STRABURAG NBU 8 EP. 4 Chapter 8-12 EP6GB0SA EP6DE0SA 0510WT

209 Maintenance Every 8000 operating hours Change the gear oil of the injection and metering drive (1). 1 Oil filling volume for gear 130 h 5,1 l (1,35 us gal.) 130 speed h 6,2 l (1,64 us gal.) 350 speed h 9,3 l (2,46 us gal.) Every operating hours Check the coupling stars (1) of the metering and injection motor; Clean the motor ventilation system of the clamping (2), metering and injection motor (3) with dry compressed air. If necessary, adjust the cleaning intervals to the actual site conditions EP6GB0SA EP6DE0SA 0510WT Chapter 8-13

210 Maintenance Replace the hydraulic hose lines. Flush the oil cooler (optional) and the cooling water fl ow controller (4) with a descaling agent. 4 Chapter 8-14 EP6GB0SA EP6DE0SA 0510WT

211 Maintenance 8.6 Hydraulic system All work on the hydraulic system must be carried out by a specialist hydraulic technician! If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! Shut off the machine at the main switch and secure the switch with a padlock against inadvertent switching on. The hydraulic system is depressurised, if the clamping plate, the nozzle and the screw are in one of their end positions. To release any residual pressure, carefully loosen (but not open) one of the hydraulic screw fi ttings Oil change Risk of injury from burns! At oil temperatures above 60 C (140 F), wear suitable protective clothing! Dispose of the spent oil according to the statutory regulations. It is the responsibility of the machine operator to dispose of the oil in a safe manner! Every 5000 operating hours, have an oil sample analysed and change the oil, if this is indicated by the analysis result. To protect the oil, do not exceed the maximum oil temperature of 60 C (140 F) and regularly replace the fi lter. To determine the local operating conditions for the adjustment of the change interval, test the hydraulic oil at shorter intervals (e.g. monthly) during the initial operating phase. The sample must be taken from the pressure line at operating temperature. The hydraulic oil must be changed every 12 months, irrespective of the operating hours. If the oil is not changed at the appropriate interval, there is an increased risk of malfunction and downtime, due to abrasive particles that have not been removed by the fi lters. EP6GB0SA EP6DE0SA 0510WT Chapter 8-15

212 Maintenance CAUTION Escaping leak oil is always contaminated and must not be returned to the hydraulic tank! Always observe utmost cleanliness! Carefully clean the fi lling nozzle on the hydraulic tank and the fi ller screws and caps at the transport and storage container for hydraulic oil. Check the hydraulic oil for contamination with water. Hydraulic oil contaminated with water is of low quality and must not be re-used! The oil must be changed immediately after a production run of the machine is completed. This ensures that the oil is at the normal operating temperature (45 C to 50 C / 113 F to 122 F) and fl ows easily. Also, at this point, the contaminants in the oil are still suspended in the oil so that they can be easily pumped off. 1 Clean the fi ller screws and caps of the transport and storage containers of the hydraulic oil. 2 Test the quality of the hydraulic oil in the storage container; see section Oil quality. 3 Filter the hydraulic oil in a mobile fi lter unit (preliminary fi ltration). 4 Switch off the hydraulic system ( Hydraulic Stop button). 5 Shut down the machine at the main switch and secure it against inadvertent switching on. 6 Clean the area around the breather fi lter. 7 Remove the breather fi lter cap and pull the entire breather fi lter from the pipe piece. 8 Empty the hydraulic tank with a pump unit through the pipe piece. The hose used for this procedure must thereby reach the bottom of the hydraulic tank. 9 Remove the tank lid and clean the hydraulic tank. CAUTION If the maximum filling level is exceeded, hydraulic oil escapes through the breather filter! Always add the new hydraulic oil through the air fi lter nozzle. This must be done with a separate fi lter unit (fi lter size 3 μm / μinch), which ensures that the oil meets the requirements of cleanliness class 15/12 according to ISO 4406 (class 6 according to NAS 1638 or CETOP RP 70 H). Experience shows that even new hydraulic liquids do not meet these standards. CAUTION Only use new hydraulic oil and never mix oils of different qualities or brands! Unless you have good reasons to do so, do not change the oil type orbrand. If you must change the oil product, first complete a flushing run with the new hydraulic oil! Chapter 8-16 EP6GB0SA EP6DE0SA 0510WT

213 Maintenance To ensure that oil products are not confused, we recommend marking the oil tank and the fi lling nozzle accordingly. 1 Using a mobile fi lter unit, fi ll the hydraulic tank to the maximum mark. The maximum mark is the upper mark in the oil level indicator. 2 Mount the breather fi lter on the pipe piece. 3 If required, reconnect the connections of the bypass fi lter unit. CAUTION Before switching on the machine, allow the hydraulic oil to settle for about 1 hour so that all air bubbles can escape! Bleeding the system After the hydraulic tank has been fi lled, you must bleed the hydraulic system. Start the hydraulic drive with the Hydraulic Start button. Press the Setup button. Move the injection unit and ejector several times back and fore across the entire stroke length. The system is properly bled, if no oil foam is visible in the hydraulic tank, all movements are performed smoothly and there are no unusual machine noises. After bleeding, check the oil level and add oil, if necessary. Only add oil of the same grade Checking the oil level The oil level must be checked constantly (at least once a day) to prevent that the oil level drops below the minimum mark. This would result in an increased operating temperature and the collection of undissolved air in the system, leading to pump failures and cavitations Return filter The return fi lter is equipped with a contamination sensor. If this sensor is triggered, an error message is displayed on the screen of the control unit. Change the fi lter cartridge (prod. no. MB628) at the next available opportunity (break in production run, e.g. at the end of a shift). If no fi lter cartridges are available in stock reorder them as soon as possible. As a rule, always change the fi lter cartridge each time the oil is changed. If it is necessary to change the oil prior to the next change interval (e.g. due to an error message or a negative oil analysis), also replace the fi lter cartridge. Utmost cleanliness is essential. The contamination sensor includes a cold start disabler, which means that the respective switch is disabled at oil temperatures below 27 C (80.6 F). EP6GB0SA EP6DE0SA 0510WT Chapter 8-17

214 Maintenance Changing the filter cartridge Switch off the IMM and wait until the system is completely depressurised. If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! Risk of injury from burns! At oil temperatures above 60 C (140 F), wear suitable protective clothing! Unscrew the fi lter cap (3). Pull the fi lter cartridge (1) with the fi lter pot (4), holding it by the bracket Remove the fi lter cartridge (1). Examine the surface for dirt particles. Such particles might indicate that components are damaged. Dispose of the fi lter cartridge (1). Before installing the fi lter cartridge, check it again to ensure that its designation corresponds to that of the removed fi lter cartridge. CAUTION Do not clean and re-use the filter cartridge! Remove the fi lter cartridge. The fi lter cartridge cannot be cleaned. Any attempt to clean the fi lter cartridge results in damage to the fi lter material, so that contaminations are not held back by the cartridge. Clean the inside of the fi lter pot (4) with a suitable agent (e.g. white spirit, petroleum), ensuring that no dirt is inadvertently moved to the clean side of the system. Examine the fi lter for mechanical damage, especially on the sealing faces and the threads. Replace damaged parts. Check the O-rings and replace damaged O-rings. Chapter 8-18 EP6GB0SA EP6DE0SA 0510WT

215 Maintenance CAUTION If damaged parts are not replaced and if the filter is not in proper working order, there is a risk of damage to other components of the system and impaired performance! Breather filter The air fi lters allow for clean air exchange as the oil level in the tank fl uctuates. Check the fi lter at least every 2500 operating hours and replace the fi lter cartridge if necessary. The check interval might need to be shortened, depending on the ambient conditions. All tasks must be carried out with utmost cleanliness Leakage Inspect the hydraulic system for leaks and eliminate them by sealing the area or retightening the respective fi ttings. Damaged hydraulic hoses and lines must always be replaced without delay. Also see section Hose lines! The hydraulic fi ttings, hoses, cylinders, valves, pumps, etc. must be checked at least every 160 operating hours Oil cooler (optional) Although the oil cooler is a maintenance-free component, we recommend servicing it every 20,000 operating hours. Dirty water must be fi ltered. Where water is hard, the cooling lines must be regularly descaled. For details, see section Water quality. EP6GB0SA EP6DE0SA 0510WT Chapter 8-19

216 8.7 Hose lines Maintenance Always adhere to the safety instructions laid down in DIN parts 4 and 5 and EN 201. The standards contain the regulations for the checking, replacement and storage of hydraulic hose lines. The operator must ensure that the hose lines are replaced at appropriate intervals, even if there is no visible damage to the hose lines that might impair their safety Service life Even if hoses are properly stored and not exposed to excessive stress, they are subject to ageing. This means that their service life is limited. Improper storage, mechanical damage and excessive stress are among the most common causes of hose failures. Do not exceed the service life (including storage time) for hoses and hose lines. Each hose and hose line is marked with the date of production. Hose lines must be replaced at least every 20,000 operating hours. Hoses, that have been used in the machine must not be re-used, as they do not meet the requirements laid down in DIN If hoses are re-used, the person remounting them will be personally responsible for any subsequent damage. Use only hose lines with a integrated sealing head. The lengths of the hose lines must be calculated according to the fi gure below. Length including standpipe ends Chapter 8-20 EP6GB0SA EP6DE0SA 0510WT

217 Maintenance Inspection criteria Every 1000 operating hours, have a specialist hydraulic technician carry out a functional test of the system. Hose lines where one of the following defects have been detected during the inspection must be replaced without delay: Damage to the outer layer and the insert (e.g. chafe marks, cracks, cuts, etc.). Embrittlement of outer layer (cracks in hose material). Deformations when pressurised or not pressurised, bent sections, separated layers and bubbles (see also DIN 20066, part 4). Leakage. Damage to or deformation of the hose fi ttings (risk of leakage); minor surface defects do not warrant a replacement. Loosening of the hose from the fi tting. Corrosion of the fi tting that might impair its function or strength. Incorrectly installed lines and fi ttings (see DIN 20066, part 4). Products whose shelf life or service life has been exceeded. EP6GB0SA EP6DE0SA 0510WT Chapter 8-21

218 8.8 Hydraulic accessories Maintenance If the hydraulic system of the machine has been equipped with additional components (e.g. bypass fi lter unit) at the request of the customer, the operator must read the relevant operating manuals included in the technical documentation, chapter Accessories. If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! Before operating the machine, read the safety instructions and operating manual for the hydraulic unit! The hydraulic unit must be installed, dismantled, configured, commissioned and serviced by authorised specialist technicians! 8.9 Water system CAUTION To protect the water lines, observe the corrosion properties of metal components when exposed to water laid down in DIN 50930! Water lines and water fi ttings must be inspected weekly by a specialist technician for corrosion and leakage. If the cooling water system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! Risk of injury from burns! At water temperatures above 50 C (122 F), wear suitable protective clothing! Chapter 8-22 EP6GB0SA EP6DE0SA 0510WT

219 Maintenance Water quality If the quality of the water at your site deviates from the guide values below, please contact our technical customers service or one of our agents. For addresses, see chapter Customer service. ph: Water hardness: < 1.8 mmol / l (681 ppm / gal) Suspended particles: < 0.03 (30 ppm) Filter mesh size: < 100 μm (0.004") As regards suspended particles and water hardness, please note that the concentration of suspended particles must be reduced the harder the cooling water. If the concentration of suspended particles is above 0.03 (30 ppm), install a water fi lter with a fi lter mesh size of < 100 μm (0.004") in front of the water system Closed cooling water circuit We recommend adding a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel). Recommended anti-freeze agent: ethylene glycol type 420 (60 % water, 40 % ethylene glycol). This additive is suitable for temperatures to -30 C (-22 F) and also serves as a corrosion inhibitor. EP6GB0SA EP6DE0SA 0510WT Chapter 8-23

220 8.9.3 Hydraulic oil temperature Maintenance Check the temperature of the hydraulic oil in the oil tank daily. For optimum effi ciency of the machine, the oil temperature should be between 45 C and 50 C (113 F and 122 F) Oil cooler Flush the cooling coils every 20,000 operating hours (at max. 16 bar / 232 psi) with a descaling agent to remove any lime scale deposits Cooling water flow controller Check the cooling water fl ow controller daily for proper fl ow and leakage. Also check the cooling water connections and hoses for unrestricted fl ow (no kinked hoses) and leakage. Clean the pipes depending on the degree of contamination of the fl ow medium. The consumers, moulds, cooling system of the screw retraction zone, etc. must be fl ushed every 20,000 operating hours with a descaling agent. Chapter 8-24 EP6GB0SA EP6DE0SA 0510WT

221 Maintenance 8.10 Electrical system For all work in connection with the assembly, dismantling, relocation and maintenance of the machine, always strictly adhere to the statutory regulations and the instructions in chapter Safety! All work on the electrical components must be carried out by a qualified electrician! Filter pads The fi lter pads can be cleaned as follows: Rinse under water (temperature not higher than 40 C / 104 F; if required, use a fi ne washing powder). Alternatively, clean by tapping, blowing out with compressed air or with a vacuum cleaner. If the fi lter pads are contaminated with greasy or oily dust, clean them with water and a grease-removing agent Buffer battery To prevent loss of data, the control unit is equipped with a buffer battery. If error message Buffer battery empty is displayed on the screen, replace the buffer battery. Replace the battery for the fi rst time after 5 years, and then every 3 years. Battery change (type: 3V/950mA lithium battery): CAUTION Operating without buffer battery results in the loss of data! Before changing the battery, take a backup of the service and mould data on a floppy disk. 1 Switch off the main switch. To prevent the loss of data, the battery must be replaced and the main switch must be switched on again within 30 seconds! 2 Ensure that all electrostatic charge is removed from the top-hat rail and the earth connector (do not reach into the power adapter). 3 Open the battery compartment with a screwdriver. To do this, place the screwdriver in the slot and lift off the cover. 4 Pull the battery from the holder by pulling the battery compartment cover. EP6GB0SA EP6DE0SA 0510WT Chapter 8-25

222 Maintenance 5 Remove the lithium battery (do not touch the battery with pliers or uninsulated pincers -> short circuit). Touch the battery only at the front side. Alternatively, use insulated pincers to remove the battery. 6 Insert the new battery, observing the polarity. Ensure that the removal strip is located below the battery as it is otherwise not possible to remove the battery at a later stage. 7 Close the lithium battery compartment cover. 8 Switch on the main switch. Dispose of the spent battery according to the statutory regulations. It is the responsibility of the machine operator to dispose of the battery in a safe manner! Chapter 8-26 EP6GB0SA EP6DE0SA 0510WT

223 Maintenance 8.11 Pneumatic system If the pneumatic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode! UNIFEED material feed unit The secondary fi lter (3)of the UNIFEED material feed unit (optional) must be checked at least once a week and cleaned, if necessary. If the machine is operated in a dusty environment, check the fi lter more frequently. The fi lter has a limited service life and should therefore be replaced immediately if there are any signs of fi bre separation (to remove the fi lter, simply slide it from the guide). The primary fi lter (2) is cleaned automatically with compressed air after each feed cycle. In the event of excessive contamination, clean the fi lter as follows: 1 Switch off the compressed air system. 2 Remove the knurled nuts (4). 3 Lift off the cover (1). 4 Clean the primary fi lter (2) and reinsert it. 5 Replace the cover. 6 Tighten the knurled nuts (4). When installing the fi lter, ensure that the O-ring is correctly placed in its position. EP6GB0SA EP6DE0SA 0510WT Chapter 8-27

224 Air purifier unit Check the oil level in the air purifi er unit (optional) every 8 operating hours and add oil, if required. For the correct oil quality, refer to the Hydraulic fl uid and lubricant table. Maintenance Filter cartridge The cleaning interval for the cartridge is determined by the purity of the ambient air. We recommend cleaning the cartridge every 500 operating hours. Switch off the compressed air system. Screw out the fi lter cartridge Mechanical closing guard The mechanical closing guard (optional) can only work properly, if all of its components are in proper working order and parts can move freely. Please note that the stop surface against which the tooth of the stop bar is pressed when in locking position is exposed to wear. Prevent malfunction of the mechanical closing guard by regularly turning and replacing the turning plate. Chapter 8-28 EP6GB0SA EP6DE0SA 0510WT

225 Spares / Plans 9 Spares / Plans The chapter Spares / Plans contains parts list, plans and drawings representing the complete range of the machine, broken down into assemblies. There is an assembly drawing for every subassembly. Each spare part can be found here listed under a position number. In order to avoid misunderstandings, it is necessary to give the Machine Number with every spare parts order. In addition please state the Identification number (ID No.), the Designation and the desired Quantity. When ordering, please contact the BATTENFELD agency responsible for you or contact BATTENFELD direct. HC4GB0TA HC4DE0TA 017WT1 Chapter 9-1

226 Spares / Plans Chapter 9-2 HC4GB0TA HC4DE0TA 017WT1

227 Special descriptions 10 Special descriptions HC4GB0UA HC4DE0UA 017WT1 Chapter 10-1

228 Special descriptions Chapter 10-2 HC4GB0UA HC4DE0UA 017WT1

229 Customer Service Contact Contact contact_2 contact 107WT1/808ES