INSTRUCTION MANUAL VM R B6 PRODUCT LINE VMRGBV Read before using the injection moulding machine and keep nearby for reference.

Transcription

1 INSTRUCTION MANUAL VM R B6 PRODUCT LINE VMRGBV 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 instruction manual Production line VM Machine model xxx/xxxx/xxxxx R XXXX Control system type UNILOG B6x Machine number 135xxx-100 Year of manufacture 2015 Numbe rof instruction manual VMRGBV02_0315 Date of issue

4

5 1...Preface Introduction Area of Applicability Explanation of symbols Copyright Certifi cate of Conformity Commissioning protocol 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 Miscellaneous Hydraulic equipment Electrical equipment Water system Pump output VM 40 - VM Pump output VM 60 - VM UNIFEED material feeder (option) Injection unit VM R... VM 40/... R VM 60/... R VM 75/... R VM 110/... R VM 150/... R VM 150/... R VM 200/... R VM 200/... R VM 270/... R Injection unit VM...VM 60...VM 80...VM VM VM Clamping unit VM R... VM 40/... R VM 60/... R VM 75/... R VM 110/... R VM 150/... R VM 150/... R VM 200/... R VM 200/... R VM 270/... R1755 VMRGBI2B 0414TW Index - 1

6 Clamping unit VM...VM 60/......VM 80/......VM 100/......VM 150/......VM 200/ Dimension of the mould Conversion table for shot weights Weights of screws and barrels Torque settings for bolts Torque settings for the fastening screws of the screw barrel head Mould mounting dimensions Foundation and installation plan 4... Transport - Installation Miscellaneous Storage Unloading Space requirement plan Transporting the machine... Transport VM...Transport VM-R... Machine weight Erecting the machine Transport safety devices Removing preservative agents Levelling the machine Hydraulic system Filling Commissioning of the hydraulic pump Deaeration Pressure vessel Bypass fi ltration unit Core puller (option) Water system Water quality Cooling water connection Cooling water fl ow governor Oil cooling Temperature control unit Pneumatic system Air supply unit UNIFEED material feeder Electrical equipment 5... Mould mounting Preparation Mould mounting Quick-action mould mounting system Interfaces Checking the safety devices Test run and interlock test Index - 2 VMRGBI2B 0414TW

7 6...Structure and function Clamping unit Clamping unit VM R Clamping unit VM Central lubrication pump Injection unit Technical description Screw drive Adjusting the nozzle centre Nozzle changing Basic requirement for changing the nozzle Changing "open nozzles Replacing the "Herzog" needle shut-off nozzle of type SHP,spring-controlled Changing the "Fuchslocher needle valve nozzle Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle,... type HP, with integrated control cylinder Replacing the pneumatically triggered "Herzog bolt valve nozzle,... type HP, with integrated control cylinder Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP Replacing the pneumatically or hydraulically triggered "Fuchslocher" needle valve nozzle ENG pneumatic needle valve nozzle with integrated control cylinder Dismantling the screw barrel / screw Dismantling the screw up to size Retooling for a different screw diameter up to size Dismantling the screw tip Cleaning the barrel, material changes Purging out with virgin polyethylene Purging out with a barrel purging agent Cleaning the screw barrel Storage Hydraulics General information Pump unit Hydraulic tank Pressure fi lter Oil cooler Control and display Pressure setting Speed setting Hydraulic oil preheating Hydraulic core puller Pneumatics UNIFEED material feeder Pneumatic core puller Air supply unit Airmould Electrics Electric drive Speed-controlled servo motor Switch cabinet UNILOG B6 control General information Operator panel Explanation of the picture Saving / Printing Control components VMRGBI2B 0414TW Index - 3

8 7... Operation Miscellaneous 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 8... Maintenance Miscellaneous Transport, storage and disposal of lubricants Disposal of electrical and electronic components Hydraulic oil and lubricant table Maintenance chart Hydraulic system Oil change Deaeration Checking the oil level Oil change Axial bearing Hydraulic fi lter Changing the fi lter element Venting fi lter Leaks Oil cooler Pressure vessel Checking the nitrogen pressure Replenishing, reducing and testing the nitrogen pressure Checking the hydraulic pressure Hose assemblies Service life Inspection criteria Hydraulic accessories Lubrication Manual grease lubrication Three phase motor Screw drive Corrosion protection Index - 4 VMRGBI2B 0414TW

9 Water system Water quality Closed cooling circuit system Hydraulic oil temperature Oil cooler Cooling water fl ow governor Electrical equipment Filter mats Buffer battery Pneumatic system UNIFEED material feeder Air supply unit Filter cartridge Mechanical scotch 9...Spares / Plans Special descriptions... Customer Service VMRGBI2B 0414TW Index - 5

10 Index - 6 VMRGBI2B 0414TW

11 1 Preface 1.1 Introduction The operating manual contains information which is deemed to support the user in his work and information which must be adhered to in order to guarantee a safe handling. The complete operating manual should be held close to the machine and be available to operating and maintenance staff at all times. 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 diffi culties, 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 specifi ed 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. Liability / Warranty Wittmann Battenfeld GmbH assumes no liability for property damage and human injury and/or environmental damage resulting from partial or full non-compliance with the operating manual. The warranty becomes invalid if unauthorised persons intervene in the equipment. In the case of personal injury, property damage or damage to the environment, claims by reason of liability or warranty shall be excluded if the damage can be attributed to at least one of the following causes: If the damage and/or failure can be traced back to the usage of spare parts other than original spare parts. Incorrect operation, insuffi cient maintenance or insuffi cient repair of the components. Operation of the components with incorrectly attached, defective or non-functional safety and protective devices. Non-compliance with the operating manual for operation, maintenance and repair. Changes made to the components without the express approval of Wittmann Battenfeld GmbH. The attachment or removal of components is particularly prohibited. Damage due to foreign bodies or force majeure. EWAGB0AC 0115TW Chapter 1-1

12 Please observe the operating manual Knowledge of the contents of the technical documentation for the components is a precondition for protecting the employees from danger, preventing errors and for operating the components in a fl awless and safe manner. Everyone entrusted with the transport, assembly, initial start-up, operation, maintenance or repair of the components must be knowledgeable of the operating manual. We recommend that the operating company require its operating personnel to confi rm in writing that they are familiar with the contents of the operating manual. All requirements and instructions in the operating manual must be complied with. All applicable national regulations, regulations for accident prevention and environmental protection and the confi rmed technical requirements for safe and proper work must be complied with. 1.2 Area of Applicability Machines of this range have been designed as standard for the processing of thermoplastics and, when using the respective injection units, 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 operating company. ATTENTION For test purposes, the injection unit was operated with the following material: Polystyrene STYROLUTION PS 454N (HIPS) processing temperature C/ F If required, rinse screw barrel with a suitable cleaning material. Chapter 1-2 EWAGB0AC 0115TW

13 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 maintenance personnel. The "Hot surface" sign indicates areas where there is a burning hazard. The operating and maintenance personnel 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! ATTENTION 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 with 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 maintenance personnel. The user must be protected by appropriate personal protective equipment. EWAGB0AC 0115TW Chapter 1-3

14 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 Certificate of Conformity The Certifi cate of Conformity is included at the end of this Section. 1.6 Commissioning protocol (For internal use only) Chapter 1-4 EWAGB0AC 0115TW

15 2 Safety 2.1 Safety regulations General information Numerous safety devices on the machine contribute to safety and accident prevention. The proprietor is responsible for the effi cient 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 modifi ed. Any unauthorised modifi cation 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 EN 201, and especially to EN ISO Unauthorised modifi cations and alterations which affect the safety of the machine are not allowed. Modifi cations 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, modifi cation and maintenance of the machine are to be recorded in a procedure. EWAGB0BB 0414MC Chapter 2-1

16 The machine is designed and built to the currently valid standard EN ISO so that the noise hazard during proper use and with optimum settings is reduced to the lowest practicable 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 mould-lifting crane from Wittmann Battenfeld GmbH 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 specifi cation plate. Even if the machine is only subject to slight modifi cations 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 fi rm, these operating instructions must be handed over with it. If is recommended to have written confi rmation of this. Chapter 2-2 EWAGB0BB 0414MC

17 2.1.2 Installation For installation, dismantling, modifi cation, 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 suffi cient 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". 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-chpt20. 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 suffi cient 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. EWAGB0BB 0414MC Chapter 2-3

18 2.1.3 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 verifi ed 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 specifi cation 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 fl ammable liquids, hazardous to health. The manufacturers' instructions are to be followed without fail. Do not use aggressive cleaning agents. Use nonfi brous 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 specifi ed on the table. Check pipework for leaks, loosened screw connections, chafe marks, and damage. Remedy detected defects immediately. Chapter 2-4 EWAGB0BB 0414MC

19 2.1.4 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 fi rst read and understand the appropriate operating instructions, especially chapter "Safety". The proprietor is advised to have this confi rmed 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 fi nished 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-fi tting 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 defi ned and adhered to so that no grey areas arise on the subject of responsibilities for safety. For all work involving assembly, dismantling, modifi cations 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 fl uids,...) must be switched off. When undertaking work involving installation, dismantling, modifi cation, operation and maintenance, no fl ammable liquid may be allowed to come into contact with components whose high temperatures could cause a fi re and explosion risk. Let the following components cool down to a safe temperature before carry out any work involving installation, dismantling, modifi cation and maintenance: Heating elements and their guardings. Temperature control units, their fi ttings, fl ow 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 fi ttings, fl ow and return lines and mounting elements. The internal cooling of the screw (option), operated with water or heat transfer oil, including all fi ttings, fl ow 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, fi ttings, fl ow and return lines and their mounting elements, and the housings of electrical motors by wearing appropriate PPE. EWAGB0BB 0414MC Chapter 2-5

20 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, modifi cation, 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, stuffi ng device, or screw opening. The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl ying 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 scope of Wittmann Battenfeld GmbH 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, modifi cations and maintenance of mould nozzles (Hot runner nozzle, Mouldmaster nozzles). When undertaking work involving installation, dismantling, modifi cation, 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.) (EN 407, EN 420, EN ISO 13732, EN 168). Chapter 2-6 EWAGB0BB 0414MC

21 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, modifi cation 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. Machines with extended tiebars (with toggle only): When setting the mounting height of the mould between guarding and clamping cylinder. 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 fi lling opening of the hopper when fi lling 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 fi xed parts. For magnetic quick-action mould mounting systems (option), the following hazards in the clamping unit area arise from: Magnetic fi elds, which, when in immediate proximity, may infl uence sensitive devices such as cardiac pacemakers, hearing aids, disks, etc. The power of the magnetic modules which can uncontrollably magnetise objects (e.g. spanners). EWAGB0BB 0414MC Chapter 2-7

22 2.1.5 Safety regulations Hydraulics / pneumatics The machine is designed and built to the currently applicable safety requirements of European Standard EN EN 4414 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, modifi cations 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 suffi cient knowledge in the fi eld 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 fl uids (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 fi res. Hydraulic hoses and hose assemblies have to be replaced at the intervals given in the "Maintenance" chapter, even if there are no defects to be detected which affect safety. Hydraulic hoses and hose assemblies must be protected from damaging external infl uences. The safety regulations for hydraulic hoses and hose assemblies to DIN and EN 201 are to be particularly carefully observed. Only hose assemblies with fi ttings that were either supplied or specifi ed by Wittmann Battenfeld GmbH should be implemented. All work involving installation,dismantling, modifi cations and maintenance of pressure vessels may only be carried out by personnel trained in this fi eld. Chapter 2-8 EWAGB0BB 0414MC

23 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 fi lled with nitrogen "N2". The use of other gases causes explosion hazards. Keep the test certifi cates 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. EWAGB0BB 0414MC Chapter 2-9

24 2.1.6 Safety regulations for the Modular Airmould System The Modular Airmould System (option) has been designed and built to the currently applicable European Standard EN ISO 12100, EN 60204, Part 1, and EN ISO 4414 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, modifi cations and maintenance may only be carried out by personnel trained in this fi eld. The Modular Airmould System must be relieved from pressure according to the descriptions in the operating manual for all work involving installation, dismantling, modifi cations 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 fi ttings that were either supplied or specifi ed by Wittmann Battenfeld GmbH should be implemented. Only hose assemblies with fi ttings which comply with or exceed DIN ISO 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 specifi ed 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 fi tting or renewal, hose assemblies must be secured so that any hazard on bursting or blowing off is prevented. After fi tting or replacing hose assemblies, the serviceability is to be checked by a trained and skilled technician. Chapter 2-10 EWAGB0BB 0414MC

25 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). The screw connection parts must meet the minimum requirements of DIN 2353, EN ISO "Solderless pipe connections with cutting ring" (Heavy Series S). Pipe fi ttings must be designed to DIN EWAGB0BB 0414MC Chapter 2-11

26 2.1.7 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 EWAGB0BB 0414MC

27 2.1.8 Safety regulations for electrics The electrical equipment on the machine is designed and built to the currently valid standards DIN EN and EN , EN 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, modifi cation and maintenance may only be carried out by a qualifi ed electrician (as defi ned in DIN VDE 0105, EN 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 specifi cations 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, modifi cation 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 fi nishing 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, modifi cation and maintenance. Not for hand-held electrical appliances suitably! No FI-protective circuit! GB Danger by current impact! At sockets with this specifi cation plate no portable hand-held electrical appliances (e.g. hand drill) may be attached. Only attach electrical appliances according to the intended use of the sockets. EWAGB0BB 0414MC Chapter 2-13

28 2.1.9 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 specifi ed by Wittmann Battenfeld GmbH may be used. When fi tting 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 plunger 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 fi tting or removing the nozzle, screw or screw barrel, no tools may be used which could cause damage to these components. Chapter 2-14 EWAGB0BB 0414MC

29 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 fi elds 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 notifi ed immediately. The amount of lubricant discharged before notifi cation 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 suffi cient 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 specifi cation sheets according to ISO (safety specifi cation 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 fi res. When disposing of electrical and electronic components, the local laws and regulations are to be observed. EWAGB0BB 0414MC Chapter 2-15

30 2.2 Table for risk assessment Reasonably foreseeable inappropriate installation / use Case Hazard Consequence Measures *) 1 Use of unsuitable materials 2 3 Use of unsuitable moulds; mould not installed Guardings are not available and the monitoring switches are disabled Overload of the machine; possibly fi re 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. 4 Operating error Loss of machine function Warnings and allowed material range in the operating manual Instructions in the operating manual Warnings, labels, instructions in the operating manual Instructions in the operating manual Reasonably foreseeable faults in installation and electrical connection Case Hazard Consequence Measures *) 1 Electrical supply (voltage, frequency, cable size) No proper functioning Permanent machine damage Instructions in the operating manual 2 Unsuitable coolant (Water fl ow rate, pressure) Blockage, overheating Permanent machine damage Instructions in the operating manual *) The given measures should only be carried out by trained operators / setters. Chapter 2-16 EWAGB0BB 0414MC

31 3 Technical data The chapter "Technical data" contains all the technical data required for normal installation, commissioning and operation of the injection moulding machine. 3.1 Miscellaneous Machine type / control Machine No. / year of construction Machine weight gross / nett Main dimensions of the IMM Noise level (DIN EN ISO ) Ambient temperature: see cover sheet see cover sheet see foundation and installation plan see foundation and installation plan VM 40 - VM db(a) C ( F) 3.2 Hydraulic equipment Hydraulic oil, tank volume see foundation and installation plan Oil temperature min / max min 35 C (95 F) / max. 65 C (149 F) Oil temperature min / max (ServoPower option) min 25 C (77 F); max. 55 C (131 F) Oil cooling trigger temperature 45 C (113 F) Oil cooling trigger temperature (ServoPower option) 35 C (95 F) 3.3 Electrical equipment Power, hydraulic pump Motor voltage frequency Screw barrel temperature see foundation and installation plan see electrical plate see electrical plate max. 350 C ( 662 F) (Option 450 C, 842 F) 3.4 Water system Oil cooler: Cooling water consumption approx. 0,5-1,5 m³ / h ( cu yd) Cooling water supply max. 22 C ( 72 F) NW 1" Oil cooler amplifi ed: Cooling water consumption approx. 0,1-1,5 m³ / h ( cu yd) Cooling water supply max. 30 C ( 86 F) NW 1" Cooling water distributor:cooling water supply Ø 3/4", 10 bar (145 psi) Cooling water return Ø 3/4" VMRGB0CC 0414TW Chapter 3-1

32 3.5 Pump output VM 40 - VM 270 Pump capacity (litres) 56 (15) 75 (20) 90 (24) 110 (29) 140 (37) 180 (48) VM 40/60 R752 X O VM 40/130 R752 X O VM 60/60 R1040 X O VM 60/130 R1040 X O VM 60/210 R1040 X O VM 60/350 R1040 X O VM 75/130 R1040 X O VM 75/210 R1040 X O VM 75/350 R1040 X O VM 75/525 R1040 X O VM 110/130 R1280 X O VM 110/210 R1280 X O VM 110/350 R1280 X O VM 110/525 R1280 X O VM 150/350 R1280 X O VM 150/525 R1280 X O VM 150/750 R1280 X O VM 150/1000 R1280 X O VM 150/350 R1520 X O VM 150/525 R1520 X O VM 150/750 R1520 X O VM 150/1000 R1520 X O VM 200/525 R1520 X O VM 200/750 R1520 X O VM 200/1000 R1520 X O VM 200/525 R1755 X O VM 200/750 R1755 X O VM 200/1000 R1755 X O VM 270/525 R1755 VM 270/750 R1755 VM 270/1000 R1755 VM 270/1330 R1755 X Standard / O Amplifi ed 200 (53) Power kw , (64) X O X O X O X O Power amplifi ed kw Chapter 3-2 VMRGB0CC 0414TW

33 3.5.1 Pump output VM 60 - VM 200 Pump capacity (litres) 75 (20) 90 (24) 110 (29) VM 60/60 X O VM 60/130 X O VM 60/210 X O VM 60/350 X VM 80/130 X O VM 80/210 X O VM 80/350 X O VM 80/525 X VM 100/130 X O VM 100/210 X O VM 100/350 X O VM 100/525 X O VM 150/350 X O VM 150/525 X O VM 150/750 X O VM 150/1000 X O VM 200/525 X O VM 200/750 X O VM 200/1000 X O X Standard / O Amplifi ed Power kw ,5 18, Power amplifi ed kw 15 18, (29) 140 (37) 140 (37) 180 (48) 180 (48) 180 (48) 200 (53) VMRGB0CC 0414TW Chapter 3-3

34 3.6 UNIFEED material feeder (option) Throughput At 6 bar (87 psi) air pressure, 100 % demand and a nominal 19 mm (0.75 inch) hose of which 4 m (13 ft) is vertical. Throughput 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) Air consumption 1 Q at 100 % demand 2 Q at 50 kg (115 lb) material / h 3 Q at 35 kg (36.29 kg) material / h Air consumed V n / min 250 HM_1046.WMF (44) 4 (58) 5 (72) 6 (87) 7 (101) Pneumatic pressure (abs.) bar (psi) Chapter 3-4 VMRGB0CC 0414TW

35 Noise level Noise level db / A 71 HM_1045.WMF 70, , , (44) 4 (58) 5 (72) 6 (87) 7 (101) Pneumatic pressure (abs.) bar (psi) VMRGB0CC 0414TW Chapter 3-5

36 3.7 Injection unit VM R VM 40/... R752 Injection unit 60 H V 130 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 13,9 22,9 34, ,8 61,4 88,4 Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 1,9 6, ,8 10,5 15,4 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 350/47 Injection flow in the open cm³/s 40,9 67, ,9 61,1 78,9 114 Injection flow outward with double pump (option) cm³/s ,5 97, Barrel heating power kw 2,3 3,3 3,8 3,3 3,8 6,5 7,8 Number of heating zones incl. nozzle 4 4 2) according to WITTMANN BATTENFELD standard VM 60/... R1040 Injection unit 60 H V 130 H V 210 H V 350 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 13,9 22,9 34, ,8 61,4 88,4 73, Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 1,9 6,2 9 4,8 6,9 12,6 18,5 9,9 14,4 22,3 11,6 17,9 28,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 350/47 300/86 300/86 Injection fl ow in the open cm³/s 49,1 81, ,1 73,4 94, , , Injection fl ow outward with double pump (option) cm³/s ,5 97, , Barrel heating power kw 2,3 3,3 3,8 3,3 3,8 6,5 7,8 6,5 7,8 10,5 7,8 10,5 12,2 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard Chapter 3-6 VMRGB0CC 0414TW

37 VM 75/... R1040 Injection unit 130 H V 210 H V 350 H V 525 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 28 41,8 61,4 88,4 73, Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 4,8 6,9 12,6 18,5 9,9 14,4 22,3 11,6 17,9 28,5 19,1 30,4 39,7 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 300/86 300/86 350/86 Injection fl ow in the open cm³/s 49,1 73,4 94, , , Injection fl ow outward with double pump (option) cm³/s 65,5 97, Barrel heating power kw 3,3 3,8 6,5 7,8 6,5 7,8 10,5 7,8 10,5 12,2 10,5 12,2 13,9 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 110/... R1280 Injection unit 130 H V 210 H V 350 H V 525 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 28 41,8 61,4 88,4 73, Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 4,8 6,9 12,6 18,5 13,1 19,2 29,7 15,4 23, ,1 30,4 39,7 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 300/86 300/86 350/86 Injection fl ow in the open cm³/s 49,1 73,4 94, , , Injection fl ow outward with double pump (option) cm³/s 65,5 97, Barrel heating power kw 3,3 3,8 6,5 7,8 6,5 7,8 10,5 7,8 10,5 12,2 10,5 12,2 13,9 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VMRGB0CC 0414TW Chapter 3-7

38 VM 150/... R1280 Injection unit 350 H V 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 18,3 28,3 45,2 22,7 36,2 47,1 27,9 36,3 43,9 32,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 300/86 350/86 350/86 500/100 Injection fl ow in the open cm³/s Injection fl ow outward with double pump (option) cm³/s Barrel heating power kw 7,8 10,5 12,2 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 150/... R1520 Injection unit 350 H V 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 18,3 28,3 45,2 22,7 36,2 47,1 27,9 36,3 43,9 32,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 300/86 350/86 350/86 500/100 Injection fl ow in the open cm³/s Injection fl ow outward with double pump (option) cm³/s Barrel heating power kw 7,8 10,5 12,2 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard Chapter 3-8 VMRGB0CC 0414TW

39 VM 200/... R1520 Injection unit 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 31 49,5 64,5 38,1 49, ,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/86 350/86 500/100 Injection fl ow in the open cm³/s Injection fl ow outward with double pump (option) cm³/s Barrel heating power kw 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 200/... R1755 Injection unit 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 31 49,5 64,5 38,1 49, ,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/86 350/86 500/100 Injection fl ow in the open cm³/s Injection fl ow outward with double pump (option) cm³/s Barrel heating power kw 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VMRGB0CC 0414TW Chapter 3-9

40 VM 270/... R1755 Injection unit 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 31 49,5 64,5 38,1 49, ,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/86 350/86 500/100 Injection fl ow in the open cm³/s Injection fl ow outward with double pump (option) cm³/s Barrel heating power kw 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle ) according to WITTMANN BATTENFELD standard Chapter 3-10 VMRGB0CC 0414TW

41 3.7.1 Injection unit VM VM 60 Injection unit 60 H V 130 H V 210 H V 350 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 13,9 22,9 34, ,8 61,4 88,4 73, Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 1,9 6, ,8 10,5 15,4 8, ,6 11,6 17,9 28,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 350/47 300/86 300/86 Injection fl ow in the open cm³/s 40,9 67, ,9 61,1 78, ,5 85, , Injection fl ow outward with double pump (option) cm³/s ,5 97, , Barrel heating power kw 2,3 3,3 3,8 3,3 3,8 6,5 7,8 6,5 7,8 10,5 7,8 10,5 12,2 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 80 Injection unit 130 H V 210 H V 350 H V 525 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 28 41,8 61,4 88,4 73, Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 4,8 6,9 12,6 18,5 9,9 14,4 22,3 11,6 17,9 28,5 19,1 30,4 39,7 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 300/86 300/86 350/86 Injection fl ow in the open cm³/s 49,1 73,4 94, , , Injection fl ow outward with double pump (option) cm³/s 65,5 97, Barrel heating power kw 3,3 3,8 6,5 7,8 6,5 7,8 10,5 7,8 10,5 12,2 10,5 12,2 13,9 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VMRGB0CC 0414TW Chapter 3-11

42 VM 100 Injection unit 130 H V 210 H V 350 H V 525 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ 28 41,8 61,4 88,4 73, Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 5,8 8,4 15,5 22,5 13,1 19,2 29,7 15,4 23, ,1 30,4 39,7 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/47 300/86 300/86 350/86 Injection fl ow in the open cm³/s 65,5 97, , , Injection fl ow outward with double pump (option) cm³/s 65,5 97, Barrel heating power kw 3,3 3,8 6,5 7,8 6,5 7,8 10,5 7,8 10,5 12,2 10,5 12,2 13,9 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 150 Injection unit 350 H V 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specifi c injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 18,3 28,3 45,2 22,7 36,2 47,1 27,9 36,3 43,9 32,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 300/86 350/86 350/86 500/100 Injection fl ow in the open cm³/s Injection fl ow outward with double pump (option) cm³/s Barrel heating power kw 7,8 10,5 12,2 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard Chapter 3-12 VMRGB0CC 0414TW

43 VM 200 Injection unit 525 H V 750 H V 1000 H V Screw diameter mm Screw stroke mm Screw L/D ratio Calculated stroke volume cm³ Specific injection pressure bar Max. screw rotational speed min Max. plastifi cation fl ow (PS)² ) g/s 31 49,5 64,5 38,1 49, ,4 39,2 48,5 Screw torque Nm Nozzle stroke / Nozzle force mm/kn 350/86 350/86 500/100 Injection flow in the open cm³/s Injection flow outward with double pump (option) cm³/s Barrel heating power kw 10,5 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VMRGB0CC 0414TW Chapter 3-13

44 3.8 Clamping unit VM R VM 40/... R752 Clamping unit VM 40/... R752 Injection unit 60 H V 130 H V Clamping force kn 400 Diameter of rotary table mm 752 Working height mm 995 Min. mould mounting height mm 250 Opening stroke / Opening force mm/kn 250/77 Max. platen distance mm 500 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/1,9 Angle of rotation/rotation time servoelectric /s 180/1,2 Dry cycle time 1) s-mm 2, ) according to Euromap 6 VM 60/... R1040 Clamping unit VM 60/... R1040 Injection unit 60 H V 130 H V 210 H V 350 H V Clamping force kn 600 Diameter of rotary table mm 1040 Working height mm 995 Min. mould mounting height mm 250 Opening stroke / Opening force mm/kn 250/132 Max. platen distance mm 500 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/2,3 Angle of rotation/rotation time servoelectric /s 180/1,3 Dry cycle time 1) s-mm 3, ) according to Euromap 6 Chapter 3-14 VMRGB0CC 0414TW

45 VM 75/... R1040 Clamping unit VM 75/... R1040 Injection unit 130 H V 210 H V 350 H V 525 H V Clamping force kn 750 Diameter of rotary table mm 1040 Working height mm 995 Min. mould mounting height mm 250 Opening stroke / Opening force mm/kn 250/132 Max. platen distance mm 500 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/2,3 Angle of rotation/rotation time servoelectric /s 180/1,3 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VM 110/... R1280 Clamping unit VM 110/... R1280 Injection unit 130 H V 210 H V 350 H V 525 H V Clamping force kn 1100 Diameter of rotary table mm 1280 Working height mm 1035 Min. mould mounting height mm 250 Opening stroke / Opening force mm/kn 250/202 Max. platen distance mm 500 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/2,9 Angle of rotation/rotation time servoelectric /s 180/1,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VMRGB0CC 0414TW Chapter 3-15

46 VM 150/... R1280 Clamping unit VM 150/... R1280 Injection unit 350 H V 525 H V 750 H V 1000 H V Clamping force kn 1500 Diameter of rotary table mm 1280 Working height mm 1065 Min. mould mounting height mm 300 Opening stroke / Opening force mm/kn 300/277 Max. platen distance mm 600 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/2,9 Angle of rotation/rotation time servoelectric /s 180/1,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VM 150/... R1520 Clamping unit VM 150/... R1520 Injection unit 350 H V 525 H V 750 H V 1000 H V Clamping force kn 1500 Diameter of rotary table mm 1520 Working height mm 1065 Min. mould mounting height mm 300 Opening stroke / Opening force mm/kn 300/277 Max. platen distance mm 600 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/3,4 Angle of rotation/rotation time servoelectric /s 180/2 Dry cycle time 1) s-mm 3, ) according to Euromap 6 Chapter 3-16 VMRGB0CC 0414TW

47 VM 200/... R1520 Clamping unit VM 200/... R1520 Injection unit 525 H V 750 H V 1000 H V Clamping force kn 2000 Diameter of rotary table mm 1520 Working height mm 1065 Min. mould mounting height mm 300 Opening stroke / Opening force mm/kn 300/327 Max. platen distance mm 600 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/3,4 Angle of rotation/rotation time servoelectric /s 180/2 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VM 200/... R1755 Clamping unit VM 200/... R1755 Injection unit 525 H V 750 H V 1000 H V Clamping force kn 2000 Diameter of rotary table mm 1755 Working height mm 1075 Min. mould mounting height mm 290 Opening stroke / Opening force mm/kn 300/327 Max. platen distance mm 590 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/3,9 Angle of rotation/rotation time servoelectric /s 180/2,4 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VMRGB0CC 0414TW Chapter 3-17

48 VM 270/... R1755 Clamping unit VM 270/... R1755 Injection unit 525 H V 750 H V 1000 H V 1330 H V Clamping force kn 2700 Diameter of rotary table mm 1755 Working height mm 1325 Min. mould mounting height mm 400 Opening stroke / Opening force mm/kn 400/445 Max. platen distance mm 800 Ejector stroke / Ejector force mm/kn 150/27,5 Cooling circuits/temperature/nominal width - threaded connection n/ C/mm 2/120/9 - G3/8" Angle of rotation/rotation time hydraulic /s 180/3,9 Angle of rotation/rotation time servoelectric /s 180/2,4 Dry cycle time 1) s-mm 4, ) according to Euromap 6 Insulating plates, adapter plates with T-slots, magnetic quick action mould mounting systems, etc. will reduce the standard mould mounting height. For the mould mounting dimensions relevant to your IMM please refer to the dimension diagram at the end of this chapter. Chapter 3-18 VMRGB0CC 0414TW

49 3.8.1 Clamping unit VM VM 60/... VM 80/... Clamping unit VM 60/... Injection unit 60 H V 130 H V 210 H V 350 H V Clamping force kn 600 Distance between tiebars mm x mm 370 x 320 Working height mm 1145 Min. mould mounting height mm 250 Opening stroke / Opening force mm/kn 375/102 Max. platen distance mm 625 Ejector stroke / Ejector force mm/kn 150/27,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 Clamping unit VM 80/... Injection unit 130 H V 210 H V 350 H V 525 H V Clamping force kn 800 Distance between tiebars mm x mm 420 x 370 Working height mm 1145 Min. mould mounting height mm 300 Opening stroke / Opening force mm/kn 375/158 Max. platen distance mm 675 Ejector stroke / Ejector force mm/kn 150/27,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VM 100/... Clamping unit VM 100/... Injection unit 130 H V 210 H V 350 H V 525 H V Clamping force kn 1000 Distance between tiebars mm x mm 470 x 420 Working height mm 1145 Min. mould mounting height mm 300 Opening stroke / Opening force mm/kn 375/176 Max. platen distance mm 675 Ejector stroke / Ejector force mm/kn 150/27,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VMRGB0CC 0414TW Chapter 3-19

50 VM 150/... Clamping unit VM 150/... Injection unit 350 H V 525 H V 750 H V 1000 H V Clamping force kn 1500 Distance between tiebars mm x mm 570 x 520 Working height mm 1295 Min. mould mounting height mm 350 Opening stroke / Opening force mm/kn 450/270 Max. platen distance mm 800 Ejector stroke / Ejector force mm/kn 150/27,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 VM 200/... Clamping unit VM 200/... Injection unit 525 H V 750 H V 1000 H V Clamping force kn 2000 Distance between tiebars mm x mm 620 x 570 Working height mm 1295 Min. mould mounting height mm 350 Opening stroke / Opening force mm/kn 450/370 Max. platen distance mm 800 Ejector stroke / Ejector force mm/kn 150/27,5 Dry cycle time 1) s-mm 3, ) according to Euromap 6 Insulating plates, adapter plates with T-slots, magnetic quick action mould mounting systems, etc. will reduce the standard mould mounting height. For the mould mounting dimensions relevant to your IMM please refer to the dimension diagram at the end of this chapter. Chapter 3-20 VMRGB0CC 0414TW

51 3.9 Dimension of the mould Dimension of the VMR mould: Minimum effective mould diameter The clamping force is applied by tiebars which, at the same time, are used as piston rods. The symmetrical 3-point force introduction ensures optimum force distribution, thus ensuring highest precision. The extremely long guide guarantees parallelism of the platens over their whole stroke. This function can only be fulfi lled if the effective diameter of the mould does not fall below a certain minimum, so that "wrap-round" of the platens is kept within acceptable limits. Since the dimensional accuracy of the mouldings, the loading on the mould and the mould's function especially with complex tooling (multi-plate tools, side actions) are affected by the wrapround of the platens, keeping to these guidelines will ensure that unacceptable overloading of the clamping unit and the mould are avoided. Thus the following minimum mould dimensions should be observed, bearing in mind an adequate clamping pressure, whch corresponds to the required clamping force, in respect of mould loading and energy consumption. Special attention must be paid to off-centre moulds and to parallelism of the mould and shutoff faces. Any defi ciency here can cause deformation of both the mould and the clamping unit, with a very detrimental effect on the service life of sealing and guiding components. Maximum mould weights The required dimensional accuracy of the mouldings, the loading on the mould and the mould's function especially with complex tooling (multi-plate tools, side actions) are heavily dependent upon the parallelism of the machine platens. The degree of parallelism required by EUROMAP 9 will be achieved if the following mould weights are not exceeded: Dimension of the VM mould: Minimum effective mould diameter The clamping force is applied by tiebars which, at the same time, are used as piston rods. The symmetrical 4-point force introduction ensures optimum force distribution, thus ensuring highest precision. The extremely long guide guarantees parallelism of the platens over their whole stroke. This function can only be fulfi lled if the effective diameter of the mould does not fall below a certain minimum, so that "wrap-round" of the platens is kept within acceptable limits. Since the dimensional accuracy of the mouldings, the loading on the mould and the mould's function especially with complex tooling (multi-plate tools, side actions) are affected by the wrapround of the platens, keeping to these guidelines will ensure that unacceptable overloading of the clamping unit and the mould are avoided. Thus the following minimum mould dimensions should be observed, bearing in mind an adequate clamping pressure, whch corresponds to the required clamping force, in respect of mould loading and energy consumption. VMRGB0CC 0414TW Chapter 3-21

52 Special attention must be paid to off-centre moulds and to parallelism of the mould and shutoff faces. Any defi ciency here can cause deformation of both the mould and the clamping unit, with a very detrimental effect on the service life of sealing and guiding components. Maximum mould weights The required dimensional accuracy of the mouldings, the loading on the mould and the mould's function especially with complex tooling (multi-plate tools, side actions) are heavily dependent upon the parallelism of the machine platens. The degree of parallelism required by EUROMAP 9 will be achieved if the following mould weights are not exceeded: Conversion table for shot weights The maximum shot weights (g / oz) are calculated by multiplying the theoretical shot volume (cm3 / cu inch) by the factors given above. The grey fi elds contain the factors for thermoset plastics. 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 hard PVC 1.12 PC 0.97 soft PVC 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 3-22 VMRGB0CC 0414TW

53 3.11 Weights of screws and barrels Load requirements for screw barrel including screw when performing a screw and barrel change. Material Screw diameter Weight [mm] [inch] [kg] [lbs] Torque settings for bolts The torque settings are listed in the spare parts list together with the screws showing different settings. These settings must absolutely be kept. The torques are based on a frictional factor of 0.10 (μmtotal) for untreated, Molykote lubricated and cadmium electroplated surfaces, but not for slightly oiled ones. Thread Nominal size Tightening torque Assembly Property class 8.8 [Nm] [lbf ft] M4 3 2 M M M M M M M M M M M27x M M33x M M36x M M M VMRGB0CC 0414TW Chapter 3-23

54 3.13 Torque settings for the fastening screws of the screw barrel head These torque settings are valid for socket head cap screws (1) for fastening the nozzle head (2). Further information on tensile strengths etc. can be found in the spare parts lists. Thread Nominal size Standard version Tightening torque Assembly Property class 12.9 [Nm] [lbf ft] M M M M Thread Nominal size High temperature heater bands Tightening torque Assembly Property class GB [Nm] [lbf ft] M M M M Mould mounting dimensions Please refer to the appendix of this chapter Foundation and installation plan Please refer to the appendix of this chapter. Chapter 3-24 VMRGB0CC 0414TW

55 4 Transport - Installation 4.1 Miscellaneous After delivery of the injection moulding machine, it should be checked immediately for any damage and/or for completeness. The machine delivery kit includes: Operating instructions. Levelling mounts (option). All the keys etc. for the switch cabinet, guarding etc. are to be found attached to the main switch. We would recommend installation of the machine to be carried out by Battenfeld personnel. We can accept no responsibility for damage resulting from improper handling. The foundation plan and installation plan can be found in the chapter "Technical Data. This chapter includes, amongst other information, the machine weights and dimensions. These must be considered when installing the machine. The installation drawings have been simplifi ed for clarity. 4.2 Storage The machine is packed as standard to withstand transportation without damage. However it should be commissioned immediately after handover from the transport company. If it is to be stored for a longer period, our customer service department has to be contacted. 4.3 Unloading Trouble free operation and some clauses of the guarantee are conditional upon proper unloading! The machine may only be lifted and moved horizontally and using the provided lifting and transport elements. It is essential that the lifting gear is prevented from slipping! Only nylon slings of sufficient length are to be used; other types of lifting gear may damage the tiebars. The safe working load of the crane and the lifting gear must equal or exceed the weight of the machine. See chapter "Technical data, Foundation and installation plan for details! Follow without fail the transport plan fixed to the machine! VMRGB0DC 0414TW Chapter 4-1

56 No persons may stand or linger under the suspended load! The complete machine may only be placed on a level surface capable of supporting the load of the machine. Trouble free operation can not be guaranteed if the complete machine is placed on an uneven floor. If there is no level surface, a foundation must be built for the machine according to the "Foundation and Installation Plan, see "Technical Data chapter, to provide a level base. If transport to the fi nal location is impossible with cranes, the machine must be supported under its entire base for moving across the fl oor. 4.4 Space requirement plan The exact space requirement can be taken from the "Foundation and installation plan in the "Technical Data chapter. A minimum space of 1,3 m (132,08 cm) must be allowed around the machine for maintenance work. Chapter 4-2 VMRGB0DC 0414TW

57 4.5 Transporting the machine This machine is equipped with a transport monitoring system. Please handle this machine according to the transport instructions. Improper handling causes a reaction of the indicator. It is absolutely necessary to state in the transport documents whether the indicator is missing or has has reacted. VMRGB0DC 0414TW Chapter 4-3

58 Transport VM 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. Before installation of the machine the safety measures detailed in DIN EN 292-2, Para must be complied with. Safety rope from size VM 100 Safety rope for integrated horizontal injection unit only Transport VM-R Safety rope from size VMR 110 Safety rope for integrated horizontal injection unit only Chapter 4-4 VMRGB0DC 0414TW

59 Machine weight Machine model Machine weight VM R (without oil) kg / lbs Machine model Machine weight VM (without oil) kg / lbs VM 40/60 R / 9500 VM 60/ / 8300 VM 40/130 R / 9700 VM 60/ / 8400 VM 60/60 R / VM 60/ / 8500 VM 60/130 R / VM 60/ / 8600 VM 60/210 R / VM 80/ / 9500 VM 60/350 R / VM 80/ / 9600 VM 75/130 R / VM 80/ / 9700 VM 75/210 R / VM 80/ / VM 75/350 R / VM 100/ / VM 75/525 R / VM 100/ / VM 110/130 R / VM 100/ / VM 110/210 R / VM 100/ / VM 110/350 R / VM 150/ / VM 110/525 R / VM 150/ / VM 150/350 R / VM 150/ / VM 150/525 R / VM 150/ / VM 150/750 R / VM 200/ / VM 150/1000 R / VM 200/ / VM 150/350 R / VM 200/ / VM 150/525 R / VM 150/750 R / VM 150/1000 R / VM 200/525 R / VM 200/750 R / VM 200/1000 R / VM 200/525 R / VM 200/750 R / VM 200/1000 R / VM 270/525 R / VM 270/750 R / VM 270/1000 R / VM 270/1330 R / VMRGB0DC 0414TW Chapter 4-5

60 4.6 Erecting the machine The machine may only be installed in a dry, dust-free environment above freezing point. The machine body completely rests on the wedge elements. Type Article number VM 60 - VM 200 VM 40 R752 - VM 150 R1280 VM 150 R VM 200 R1755 VM 270 R1755 Oscillating element NMS 160/M16 100NE Oscillating element LE 190/M20 100NE018 8 Adjustment of the oscillating elements Adjustment is made by means of the hexagon bolt, and the height of the oscillating element may vary between 59 mm and 89 mm. A hexagonal nut (2) is used as a lock nut to fi x the height adjusted by the screw (1). 2 1 Artikel Nr. Type Heigh Setting range 100NE014 NMS 160/M NE018 LE 190/M Chapter 4-6 VMRGB0DC 0414TW

61 4.7 Transport safety devices VMR transport safety device: The transportation devices (pos1, 3x) must be removed before commissioning and must be reattached without fail before moving the IMM again! 1 1 VM transportation device: The transportation devices (pos1, 2x) must be removed before commissioning and must be reattached without fail before moving the IMM again! 1 VMRGB0DC 0414TW Chapter 4-7

62 4.8 Removing preservative agents All unplated moving parts and guides (tiebars, piston rods, etc.), and all unpainted, unplated bolts must have the rust protection removed, using cloths soaked in white spirit, paraffi n (kerosene) or similar solvents. Small components delivered with the IMM such as screw tips and stop rings are protected by wax dipping. The wax coating should be removed before use. ATTENTION Even a single stroke without removing the corrosion protection can drive it into the guides and lead to wear! These cleaning fluids are considered hazardous to health and are flammable. Follow the manufacturers instructions! The local regulations must be observed when disposing of these liquids and cloths soaked in them! Injection unit Nozzle contact cylinder piston rods. Guide rails Injection unit 3 Hopper base plate 4 Hopper throat safety grid 5 Barrel, screw shaft and coupling Chapter 4-8 VMRGB0DC 0414TW

63 VMR clamping unit: Mould mounting surfaces 2 Tiebars VM clamping unit: Mould mounting surfaces 2 Tiebars VMRGB0DC 0414TW Chapter 4-9

64 4.9 Levelling the machine The injection moulding machine may only be installed in a dry, dust-free environment above freezing point. The machine body must completely rest on the levelling mount or the wedge elements. Levelling the VMR machine: A machine spirit level with an accuracy of 0.1 mm / m (0.004 inch / ft) are essential for levelling the injection moulding machine. In addition, the machine must be equipped with levelling mounts or wedge elements (option). The machine spirit level is laid to the rotary table and, by means of the levelling mounts, levelled lengthways and across the injection moulding machines to 0.2 mm/m (0.008 inch / ft). Levelling the VM machine A machine spirit level with an accuracy of 0.1 mm / m (0.004 inch / ft) are essential for levelling the injection moulding machine. In addition, the machine must be equipped with levelling mounts or wedge elements (option). The machine spirit level is laid to the mounting platen and, by means of the levelling mounts, levelled lengthways the injection moulding machines to 0.2 mm/m (0.008 inch / ft). Chapter 4-10 VMRGB0DC 0414TW

65 4.10 Hydraulic system Work at the hydraulic system may only be carried out by a skilled hydraulic technician! If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury! If the clamping platen, nozzle and screw are not in one of their end positions then the hydraulic system is relieved from pressure. Any residual pressure can be released by carefully loosening (but not completely undoing) a hydraulic screw connection. In case of hydraulic systems with pressure vessels (option) you have to wait until the system has been completely relieved from pressure. See also the paragraph "Checking the hydraulic pressure" in chapter "Maintenance". Turn off the mains switch and secure it against accidental reconnection Filling The oil fi ller neck (1) is on the rear of the machine. 1 ATTENTION The machine s hydraulic unit requires oil of the cleanliness class 17/15/12 according to ISO Contamination above this cleanliness class by improper filling or use of unsuitable hydraulic oil will invalidate the guarantee! If hydraulic oil becomes contaminated with water it will be of inferior quality and must not be used any further! The hydraulic tank may only be fi lled with hydraulic oil as detailed in the "Maintenance" chapter. The required volume of oil can be found in the foundation and installation plan (chapter "Technical data"). VMRGB0EB 0414TW Chapter

66 ATTENTION Test the hydraulic oil for the possible ingress of water! Never switch the machine on without hydraulic oil. Even the shortest period of running will damage hydraulic equipment! When fi lling for the fi rst time the following sequence must be followed without fail: Clean the fi ller screws and the screw plugs on transport and storage containers. Verify the grade of oil; see "Maintenance" chapter Prefi lter the hydraulic oil through a mobile fi ltration unit with a 3 μm ( μinch) mesh. Make sure that the main switch is switched off and secured against accidental reconnection. Remove guarding if necessary. Clean around the fi ller and venting fi lter. Remove the lock of the fi ller and venting fi lter (the fi lter screen must remain in place for fi lling). Filling the oil tank for the first time ERROR[Grundlegender Syntaxfehler] in:<p)error[grundlegender Syntaxfehler] in:> Fill hydraulic tank to the maximum oil level through a mobile fi ltration unit with 3 μm ( μinch) mesh until the fl oat in the oil sight glass has exceeded the max. marker. The oil sight glass is located at the clamping side front of the machine. MAX MIN Switching level 50 mm (1,97 inch) HM_1014.PMP ATTENTION Before switching on the machine, the hydraulic oil should be allowed to stand for approx. 1 hour to let the air trapped during filling escape! Chapter VMRGB0EB 0414TW

67 Commissioning of the hydraulic pump Activation of the pump rinsing program for pump system 1 and pump system 2 if present (option) UNILOG B6 ATTENTION Before switching on the hydraulic pump the hydraulic motor s direction of rotation should be checked! Start the machine If there is air present in the pump system, e.g. due to a pump or oil change, activate this program to eliminate the air from the system The pump rinsing program is to be activated for 20 minutes approx. The program has to be deactivated afterwards The oil heating starts if the oil operating temperature has not been reached with the pump rinsing program If the clamping unit is in the "open" position, move the clamping unit to the front position (refi ll oil if necessary) and carry out a complete dry cycle (oil is distributed in the system) If the clamping unit is in the "closed" position, slowly open the clamping unit and observe the oil sight glass. If the oil level exceeds the visible part of the gauge, oil must be removed to carry out a complete dry cycle (oil is distributed in the system) If the oil level is lower than the min. marker after this process and the oil level detector emits an error message, only fi ll in oil until the error message can be acknowledged VMRGB0EB 0414TW Chapter

68 During machine operation, the oil level should be between the max. and the min. marker If the tank is filled above the maximum level, hydraulic oil will come out of the venting filter! In this case, the suction pipe and the filter housing have to be cleaned and the filter insert has to be replaced. Remount the fi lling and venting fi lter onto the pipe socket. Attach guarding if necessary Deaeration After fi lling the hydraulic tank air must be bled from the hydraulic system. Connect power; see "Electrical equipment" paragraph Connect cooling water; see "Water system" paragraph. Press the "Hydraulic start" key to switch on the hydraulics Press the "Setting" key. Open and close all safety gates. Drive the clamping platen, nozzle and screw forward and backward over their whole stroke several times. Bleeding is carried out effectively when no foam appears in the hydraulic tank, movements are smooth and there are no strange noises. The oil level should be checked after bleeding and topped up if necessary. Care must be taken to use the same oil type. Any oil leaks arising after a few operating hours are usually cured simply by tightening the screw connections. Chapter VMRGB0EB 0414TW

69 Pressure vessel Pressure vessels (option) integrated into the hydraulic system allow increased injection output. Work on plants with pressure vessels may only be carried out by a specially trained technician! 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! Before starting up the machine the nitrogen pressure within the pressure vessel must be checked. In case the nitrogen pressure falls short of the indicated value (see name plate), nitrogen has to be refi lled. Pressure vessels are subject to the safety regulations applicable at the place of use. Before starting up the machine, they have to be accepted by the technical standards organisation (e.g. TÜV) responsible in the proprietor s region. The proprietor of pressure vessels is responsible for ensuring the proper condition, operation and monitoring. Neither welding nor soldering nor any mechanical processing may be performed on the pressure vessels. Improper repairs can cause severe accidents and may only be carried out by authorised customer service personnel. Replenishing, reducing and testing the nitrogen pressure ATTENTION The nitrogen pressure changes temperature dependently. For this reason, inspections should always be carried out under equal temperature conditions. After filling or discharging nitrogen please wait 5 minutes approx. until the temperature has been balanced. Check the gas pressure afterwards! During each check nitrogen will escape through the filling unit. This will reduce the nitrogen pressure, especially in case of small pressure vessels! The pressure within the mobile nitrogen cylinder (for filling the pressure vessel) may not exceed the maximum permissible operating pressure of the machine s pressure vessel or the pressure gauge. Otherwise a pressure reducer has to be inserted between the mobile pressure cylinder and the filler! Please keep all certificates in a safe place! When demanding certfi cates later on, please state the contents, the factory number and the year of manufacture of the vessel. These data is embossed on both ends of the vessel. VMRGB0EB 0414TW Chapter

70 Non-return valve (valve insert) 2 - Button 3 - Valve gate 4 - Pressure pin 5 - Venting valve 6 - Union nut 7 - Seal element 8 - Connection piece (SAE 7/8" - 14UNF -2B) 9 - Gas fi lling valve 10 - bubble accumulator 1 Screw a pressure gauge connection-hose assembly Nominal diameter ND2; G 1/4 (option) to the fi tting of a pressure gauge, 0 to 600 bar / 8700 psi (option), not included in the standard delivery 2 Clean the surroundings of the miniature measuring connection at the hydraulic block of the pressure vessel. 3 Remove the sealing cap of the miniature measuring connection. 4 Screw in the fi tting of the pressure gauge connection-hose assembly. 5 Switch off the machine at the main switch. 6 Wait for the pressure of the hydraulic oil within the pressure vessel to be reduced (until the pressure gauge indicates 0 bar / psi). 7 Unscrew the covering cap(s) of the gas fi lling valve. 8 Screw the fi ller unit to the gas fi lling valve. 9 Check whether the venting valve of the fi ller unit is closed. 10 Screw the hose assembly s connecting piece to the nitrogen bottle. 11 Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly fl owing into the pressure vessel (for the fi lling pressure please refer to the hydraulic plan or the respective label). 12 Close the shut-off valve after reaching the desired nitrogen pressure. 13 Use the venting valve to close the fi lling hose. 14 Press the button of the fi ller unit, release it and read off the nitrogen pressure at the pressure gauge. 15 In case the nitrogen pressure is too high, carefully press the pressure pin after opening the venting valve to reduce the pressure. Steps 10, 11 and 12 will be omitted when reducing or checking the pressure. Chapter VMRGB0EB 0414TW

71 Bypass filtration unit By using a bypass fi ltration unit the machine s downtime will be considerably reduced by having longer service and maintenance intervals. For this purpose connection points on the back of the tank for the return line from the bypass fi ltration unit and the fl ow from the hydraulic tank to the bypass fi ltration unit are provided. The bypass fi ltration unit must be connected with the hydraulic tank empty if the shut-off valves (option) are not fi tted. After proper connection of the supply and return lines, the shut-off valves must be opened before the bypass fi ltration unit is started up Core puller (option) see Chapter "Strucuture and Function" Pneumatic core pullers may only be fitted and put into operation by a pneumatic technician! The safety regulations in the chapter "Safety" are to be followed without fail! VMRGB0EB 0414TW Chapter

72 Chapter VMRGB0EB 0414TW

73 4.11 Water system ATTENTION When installing water pipework note the corrosion stability of metallic materials against water in accordance with DIN 50930! Water quality If there are deviations from the following guidelines, please contact our technical customer service or one of our subsidiaries. The addresses can be found in the "Customer service" chapter. ph value: 6,5-9 Water hardness: < 1.8 mmol/l (681 ppm/gal) Solids: < 0.03 (30 ppm) Filter mesh: <100 μm (0.004 mm) In the relation of solids content to water hardness, it should be noted that the harder the cooling water is the lower the solids content has to be. If the level of suspended matter is over 0.03 (30 ppm), a water fi lter with a mesh size <100 μm (0.004 inch) must be fi tted before the water system. It is also recommended to add a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel). We recommend ethylene glycol type 420 as an antifreeze (60 % water and 40 % ethylene glycol). This is suitable for a temperature range down to -30 C (-22 F) and is also a corrosion inhibitor Cooling water connection 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! The cooling system for the IMM can also be run as a closed cooling system. The purest, most chalk-free water should be used. The required nominal diameters of the hoses are quoted in the chapter "Technical data". The bore of the fl ow and return lines must not be smaller than those of the connections on the IMM. EWAGBFC 0115TW Chapter

74 Cooling water flow governor The cooling water fl ow governor provide cooling water for various users, such as mould, screw barrel, etc., from a common water supply. The cooling water fl ow rate and thus the temperatures of the various consumers are controlled by the appropriate hand-wheels Common fl ow to cooling water fl ow governor 2 Common return from cooling water fl ow governor 3 Flow to user 4 Return from user 5 Hand-wheel to control cooling water fl ow to user 6 Hand-wheel to control cooling water return from user 7 Thermometer to show cooling water return temperature 8 Bobbin to show fl ow rate 9 Marker-ring to mark preset fl ow rate 10 Scale for setting Burning hazard if touched! Wear suitable PPE with water temperatures above 50 C (122 F)! Injury hazard to operating and other personnel and possible damage to cooling water flow governor if used at improper temperatures and pressures! Chapter EWAGBFC 0115TW

75 The cooling water pressure must be set for different temperatures according to the following table: Temperature max. pressure 40 C (104 F) 10 bar (145 psi) 60 C (140 F) 8 bar (116 psi) 80 C (176 F) 6 bar (87 psi) The cooling water hoses must be routed so that unhindered water supply and return are ensured. Kinks and squeezing will prevent the optimised fl ow of the cooling water. Water assemblies have to be expertly installed and laid. Fittings, length and cross section have to meet the requirements! Make sure the hoses are long enough to allow for movement of the various units. The hoses must be suitable for the system pressure (max. 10 bar psi) and the ambient temperatures used (max. 80 C F) Before the cooling water fl ow governor is connected it must be ensured that the hand-wheels (5 and 6) are closed clockwise. Next, the various users are connected to the cooling water fl ow governor (3 and 4). Now the cooling water fl ow governor is connected to the cooling water system (1 and 2). By turning the two hand-wheels (5 and 6) counterclockwise, the cooling water fl ow is opened and the required fl ow rate can be set. Using the marker ring (9), the required fl ow rate can be marked so that the desired fl ow rate can be set again easily after a user has been turned off. The fl ow rate set can be calculated from the bobbin's (8) position in the water stream and the scale (10) using the following chart. Flow range per circuit Brass bobbin Temperature Pressure 0,5-10 l/min ( imp.gal/min) max. 80 C (176 F) max. 10 bar (145 psi) EWAGBFC 0115TW Chapter

76 Oil cooling The hydraulic oil is cooled in a heat exchanger. In which the cooling water is passed through a cooling coil surrounded by the hydraulic oil. A solenoid valve regulates the water fl ow. By allowing or interrupting the cooling water supply it achieves a constant oil temperature. A temperature sensor in the hydraulic tank measures and monitors the oil temperature and sends the actual values to the IMM's control unit. This in turn orders the solenoid control valve to be opened or closed. Water assemblies for cooling the hydraulic system have to be expertly laid and installed. Fittings, length and cross section have to meet the requirements! The cooling water hoses must be routed so that unhindered water supply and return are ensured. Kinks and squeezing will prevent the optimised fl ow of the cooling water. The hoses must be suitable for the system pressure and the temperatures reached in use. The optimum effi ciency of the injection moulding machine is at an oil temperature between 45 C and 50 C (113 F and 122 F) HLP 46, with HLP 32 between 35 C and 40 C (95 F and 104 F). The maximum temperature of the supplied water must not exceed 22 C, 72 F, (30 C, 86 F) with reinforced oil cooler. Cooling water consumption conditions Oil side max. Water side max. Water Oil-Water 16 bar (232 psi) 10 bar (145 psi) 2 m/s (1,8 yd/s) 25 C (77 F) Temperature control unit Temperature control units (option) are used for liquid temperature conditioning of moulds, barrels and screws. Before operating the IMM its Safety regulations and those of the temperature control unit must be observed without fail! A temperature control unit may only be installed by a qualified electrician (according to DIN VDE 0105, IEC 364 or equivalent)! The installation, connection and commissioning of the temperature control unit are detailed in the separate Operating Manual and in the corresponding wiring diagram in the "Spare parts / Plans" chapter. The standard location for the connection(s) is on the side of the switch cabinet. Chapter EWAGBFC 0115TW

77 4.12 Pneumatic system Compressed air piping for the pneumatic system must be expertly laid and installed. Fittings, length and cross section have to meet the requirements! Work at the pneumatic system may only be carried out by a skilled pneumatic technician! 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! Air supply unit Setting knob pressure control valve 2 Condensate separator 3 Pressure gauge 4 Condensate reservoir 5 Drain screw Turn pressure valve control knob (1) clockwise until the desired pressure (min. 6 bar - max. 10 bar / min. 87 psi - max. 145 psi) is shown on the pressure gauge (3) EWAGB0GB 0814TW Chapter

78 UNIFEED material feeder The UNIFEED material feeder (option) replaces the hopper so that production is not interrupted by fi lling the hopper. It is especially suitable for feeding the following polymer granulates: PE-HD, PE-LD, PS, PA, PA + GF, PP, ABS, POM, PPO. The UNIFEED material feeder is well suited to conveying regrind and virgin materials together. The particle size, however, must no be larger than 3-4 mm ( inch). If the material feeder is located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for filling! Move the climbing aid in front of the IMM. Place the material feeder on the hopper support and fi x with 2 bolts (in delivery kit). Line up the suction tube with the mounting holes on the material reservoir. Fit the air valve and proximity switch and connect according to wiring diagram. Chapter EWAGB0GB 0814TW

79 Position the proximity switch directly on the plexiglass and adjust it with the adjusting screw so that the LED lights up when the tube is full and goes out when the tube is empty. Attach the compressed air hose (ND 10 mm / 0.4 inch) to the connecting branch and fasten with a hose clip. The compressed air hose must be laid so that an unrestricted supply of compressed air is guaranteed. Take care not to kink or crush the hose. The hose must be long enough to allow for the movement of the injection unit. The hose must be suitable for the system pressure (max. 7 bar psi) and the temperatures reached in use. EWAGB0GB 0814TW Chapter

80 Chapter EWAGB0GB 0814TW

81 4.13 Electrical equipment The IMM may only be connected to a power supply which corresponds in phase, voltage and frequency to the data given on the electrical specifi cation 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 IMM with two separate supplies for the motor and heating circuits. If the IMM 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, E) HM6GB0HA 0414TW Chapter

82 3 - Separate leads for drive and heating without neutral 1T2 2T1 2T3 1T1 1T3 2T2 4 (L1, L2, L3, E) 4 (L1, L2, L3, E) 4 - Separate leads for drive and heating with neutral 1T2 2T1 2T3 1T1 1T3 2T2 N 4 (L1, L2, L3, E) 5 (L1, L2, L3, N, E) Checking the direction of rotation of the hydraulic pump s drive Before switching on the IMM it must be ensured that: The hydraulic system is sealed, the switch cabinet is closed, the hydraulic tank is fi lled and the hydraulic pump(s) has/have been primed. The guarding and safety gates have been properly fi tted and are closed. CAUTION The pump will not work correctly if the direction of rotation is wrong and the drive and the hydraulic pump will fail! Connect the supplies as described in paragraph "Electrical equipment". The hydraulic motor s direction of rotation may only be tested by a qualified electrician! Open the electrical cabinet. Connect a phase sensor to lines 1L1, 1L2 and 1L3 on the main switch. Chapter HM6GB0HA 0414TW

83 Switch on the supply voltage (low voltage distribution). The phase sensor should now indicate a right-hand (clockwise) fi eld. 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. Finally start the hydraulic pump(s) in "Setting mode" and allow to run for a few seconds without load in order to lubricate the hydraulic pump(s). HM6GB0HA 0414TW Chapter

84 Chapter HM6GB0HA 0414TW

85 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 fl ange 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 specifi cation (see chapter "Technical Data"). Check that the water fi ttings 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 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 VMRGB0IB 0914TW Chapter 5-1

86 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 fi nd out how to clear them. Once all the errors are cleared and the drive is started, mould mounting can be continued. 11 Press the "Setting mode" key, press the "Open mould" key, and open the nozzle platen. 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! 11.1 The mould halves must be prevented from sliding apart. Chapter 5-2 VMRGB0IB 0914TW

87 11.2 Hang the mould into the lifting equipment. Danger of death! It must be ensured that no persons stand or linger under the suspended load! 11.3 Turn the rotary table (station C) in the setting mode until the ejector coupling is in the position for inserting the mould Introduce the mould into the centering hole of the rotary table, align it and fasten it by means of muld clamps. The lifting equipment should not be removed until the mould is bolted securely on the rotary tabletop and this has been verified by an authorised technician! Do not loosen the safety strap holding the two mould halves together! ATTENTION The number of mould clamps must be adapted to the mould weight and the opening force of the machine! 11.5 In the setting mode, turn the rotary table into the clamping station (station A) 11.6 Remove the safety strap holding the two mould halves together Close the clamping unit in the setting mode. ATTENTION Check during closing that the upper part fits into the alignment ring! 11.8 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. VMRGB0IB 0914TW Chapter 5-3

88 min.1.5d 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 For adjusting the zero points of the mould "Zeroising Clamping unit" refer to the chapter "Machine in general / Zeroising". 12 Clamping the mould to the clamping platen 12.1 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 nozzle platen For installing several lower moulds, paragraphs 11.3 to 12.4 must be repeated. Chapter 5-4 VMRGB0IB 0914TW

89 13 Set clamping force 13.1 Press the "Manual operation" key Press the "Clamping unit" menu key. The "Clamping unit" page appears If the input fi eld "Clamping force" is pressed, the "Numpad" appears. Here, the wished clamping force can be entered in "kn" (shtn) (see also User manual A5) Press the "Mould Close" key and close the clamping platen Set the nozzle zero point, see chapter VMRGB0IB 0914TW Chapter 5-5

90 14 Log off from the control ATTENTION To prevent set value entries by unauthorised persons, the user must log off after finishing setting! 14.1 An activation of the key symbol opens the window for "System password". If you want to interrupt or fi nish your work at the control unit, you will have to logout fi rst. 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". 15 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. 16 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. Chapter 5-6 VMRGB0IB 0914TW

91 5.3 Quick-action mould mounting system Use the "Mouldfi x" 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 Press the "Setting mode" key. 3 Close clamping platen. 4 Move injection unit fully back. Only then may the wedge clamping elements of the "Mouldfi x" be moved out (released). 5 Switch on "Mouldfi x" program switch (refer to User manual Chapter 3.5) 6 Move out (release) the wedge clamping elements of the "Mouldfi x" 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. VMRGB0IB 0914TW Chapter 5-7

92 9 Clamp the upper mould to the nozzle platen by activating the wedge clamping elements of the "Mouldfi x" 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. 10 Switch off "Mouldfi x" program switch (refer to User manual Chapter 3.5) Remove key for latching and releasing the mould 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. 5.4 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. Chapter 5-8 VMRGB0IB 0914TW

93 5.5 Checking the safety devices The safety devices can only fulfi l 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 fi xed limit switches. Hydraulic interlock: Proper function and securely fi xed limit switch. Mechanical scotch (option): Proper function and free movement of swinging scotch (fl ag) on the clamping platen and the correct position (teeth) of the scotch bar. 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: free movement and securely fi xed limit switches Purge guard, safety gate and guarding: Security of all fi xing bolts and undamaged condition and proper function 5.6 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 fi ttings for security Close safety gates and check for proper fi tting 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. VMRGB0IB 0914TW Chapter 5-9

94 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. Open and close the clamping unit s safety gate (to check the safety gate monitoring). 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. Switch on drive ("Drive On" key). 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 5-10 VMRGB0IB 0914TW

95 6 Structure and function Clamping unit 6.2 Injection unit 6.3 Hydraulic (option) 6.4 Pneumatics (option) 6.6 Electrics 6.7 Control VMRGB0JB 0414TW Chapter 6-1

96 Chapter 6-2 VMRGB0JB 0414TW

97 6.1 Clamping unit Clamping unit VM R Technical description 1 Rotary table 2 Support platen 3 Nozzle platen 4 Connecting platen Piston rod 5 3 clamping cylinders 6 Piston rod 7 Connecting platen Cylinder 8 Guide rails (for horizontal injection unit only) 9 Tiebar nut VMRGB0KC 0414TW Chapter 6.1-1

98 Description of functions: The clamping unit can be considered as an independent assembly attached to the machine body by bolts in the support platen for the rotary table. The clamping force is applied by three clamping cylinders. The symmetrical 3-point force introduction ensures optimum force distribution. This system guarantees highest precision during the movements of the clamping unit. As standard, the hydraulic ejector is mountet to (station C). The bearing of the rotary table is located on the support platen, thus the rotary table can be turned around the front tiebar. The rotary table is driven by a hydraulic motor/servo-motor. The rotary movement of the motor is transmitted to the rotary table with external toothing by means of a pinion. Position determination of the rotary table is made via the shaft encoder. An index cylinder ensures the exact positioning of the rotary table. Mould mounting The mould can be mounted from the front with the appropriate lifting gear. The mould should be positioned oin the nozzle platen by means of an alignment ring. The fastening can be carried out in different ways: Direct screwing down on four threads for each mould half in the nozzle platen and on the rotary table. Fastening by means of four mould clamps for each mould half. Mouldfi x (option). Magnetic mounting platens (option) Chapter VMRGB0KC 0414TW

99 6.1.2 Clamping unit VM Support platen 2 Ejector 3 Nozzle platen 4 Connecting platen Cylinder 5 Connecting platen Piston rod 6 4 clamping cylinders 7 Guide rails (for horizontal injection unit only) 8 Piston rod 9 Tiebar nut VMRGB0KC 0414TW Chapter 6.1-3

100 Description of functions: The clamping unit can be considered as an independent assembly attached to the machine body by bolts in the mould mounting platen. The clamping force is applied by four clamping cylinders. The 4-point force introduction ensures optimum force distribution. This system guarantees highest precision during the movements of the clamping unit. Mould mounting The mould can be mounted from the front with the appropriate lifting gear. The mould should be positioned oin the nozzle platen by means of an alignment ring. The fastening can be carried out in different ways: Direct screwing down on four threads for each mould half in the mounting platen. Fastening by means of four mould clamps for each mould half, which must be diagonally alligned on each mounting platen. Mouldfi x (option). Magnetic mounting platens (option) Chapter VMRGB0KC 0414TW

101 6.1.3 Central lubrication pump Design: 1 Direct current motor 2 Screw drive 3 Eccentric shaft 4 Piston 5 Piston outlet screwing 6 Delivery piston 7 Grease sieve 8 Agitator blade 9 Grease container 10 Follow-up piston 11 Conical-screw spring 12 Tracer pin 13 Overfi ll protection VMRGB0KC 0414TW Chapter 6.1-5

102 Description of functions The central lubrication pump is an electrically driven lubrication pump. In the standard verisin the pump is equipped with an electrical level indication. When reaching the minimum grease level, this level indication will switch off the pump so that no air can be sucked into the system. The lubrication intervals depend on the machine working cycles and the size of the rotary table. On delivery of the IMM, the following lubrication cycle has been defi ned: Lubricant quantities series VM R KLÜBERSYNTH GE Diameter of rotary table 752 mm 896 mm 1040 mm 1280 mm 1520 mm 1755 mm Lubrication points Lubricant quantity (cm³) / lubrication cycle Lubricating time (sec.) Lubrication intervals after cylces Quantites of lubricant (kg) / 10 mio. cycles Position of the central lubrication pump on the machine Chapter VMRGB0KC 0414TW

103 6.2 Injection unit Technical description The main components of the injection unit (or carriage) are the screw barrel (1), the nozzle contact cylinder (2), the injection cylinder (3), the drive and bearings (4), hydraulic motor (5), the material hopper and the support. Low maintenance linear bearings enable precise axial movements of the injection unit. The mechanical stop prevents any movements out of the linear bearings when dismantling the screw. The two nozzle contact cylinders are designed as double-acting hydraulic cylinders. The piston rods are designed as guide rails and are attached to the nozzle platen. The nozzle contact cylinders have a long stroke so that the nozzle is easily accessible when the carriage is moved right back. A stroke transducer, on the rear side of the machine, records the movements of the nozzle contact cylinders and transfers them to the machine control. The screw is driven directly by a low speed hydraulic motor. This minimises the rotating masses. The torque of the hydraulic motor is suited to the load at any time. VMRGB0LA 0914TW Chapter 6.2-1

104 A proximity switch records the screw speed and transfers it to the control. A stroke transducer, on the rear side of the machine, records the stroke of the screw and transfers it to the machine control. The injection unit ensures a high plasticising rate, achieved partly by an optimised L/D (= length / diameter) ratio. The barrel and the nozzle are equipped with ceramic heater bands. Different heat outputs and zones can be obtained by arranging of several heater bands side by side. ATTENTION To ensure a long service life for the screw barrel heater bands, they should be checked for secure fitting when hot at regular intervals, starting with commissioning! Depending on the moulding compound to be processed, the heating of the screw barrel is additionally equipped with an outside cooling (option) by means of radial fans or with a cooling by means of heat transfer oil (option). The material hopper which is used for receiving the moulding compound can be easily removed by undoing one fi xing bolt. The hopper outlet can be closed with a slide. A magnet (option) in the material hopper is used for separating steel particles from the moulding compound. This procedure is recommended especially when processing regranulated material. Three continuously adjustable brackets allow adjusting the magnet to the desired distance to the wall of the material hopper. Chapter VMRGB0LA 0914TW

105 6.2.2 Screw drive Before checking, the machine must be switched off at the main switch and must be secured against accidental reconnection! The axial bearing of the injection unit is arranged so that the leakage line from the hydraulic motor lubricates it. No maintenance is thus necessary in this case. The oil level must be checked before the fi rst start-up and, if necessary, oil must be fi lled in or refi lled in the "Axial bearing" of injection unit 8800 and if the servo-motor option is installed. Only a slide oil according to DIN 51502, CGLP 220, DIN (ISO : L-C) may be filled in. For the demands on the lubricant refer to the paragraph "Hydraulic oil and lubricants". Care must be taken to use the same type of gear oil. The oil level (1) should be checked daily. If no gear oil can be seen, gear oil must be added (2) or an oil change carried out. Horizontal injection assembly: 2 1 Vertical injection assembly: 2 1 For the oil change and the intervals, please refer to the "Maintenance" chapter. The axial bearing should be checked daily for leaks and damage to the shaft seals. VMRGB0LA 0914TW Chapter 6.2-3

106 6.2.3 Adjusting the nozzle centre Injection unit up to size 1330 Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! 1 Measure the centricity of the nozzle with a caliper gauge by measuring the distance from the nozzle bore to the opening in the platen at several places - at least four. The tolerance must not exceed 0.2 mm (0.008 inch). 2 Use the 3 set screws (1) after unscrewing the locking nuts (2) to move the screw barrel into the required position. In this process, always unscrew the "opposite" set screws and tighten after the adjustment to avoid twisting the screw barrel. 3 Retighten locking nut (2) and set screws (1). 4 Then carry out another measurement for test purposes. Chapter VMRGB0LA 0914TW

107 6.2.4 Nozzle changing Working data Shut-off nozzles Herzog Typ SHP Activation Spring max. injection flow (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 Setting instructions of the external shut-off cylinder pneumatic / hydraulic: Nozzle closed: Needle contacts the nozzle point, piston in the shut-off cylinder in fl oating position - minimum distance to unit > 1mm Nozzle open - Herzog system: Needle shoulder contacts nozzle body, lever is retracted from the needle, however, does not touch the basic body, piston of the shut-off cylinder in limit position on unit Nozzle open - Fuchslocher system: Needle with cross yoke contacts nozzle body, lever will rollers is retracted from the cross yoke > 1 mm, piston of the shut-off cylinder in limit position on unit Guide values of the lever strokes - setting stroke of shut-off cylinder - see table VMRGB0LA 0914TW Chapter 6.2-5

108 Basic requirement for changing the nozzle 1 Press the "Setting" key. 2 Set peripheral equipment (option) to the starting position and switch off any peripheral equipment according to its operating manual. 3 Switch off material feeder (option). ( ) Only for Airmould nozzle:shut off the nitrogen supply to the Airmould pressure generation unit. If appropriate, switch off the Airmould nitrogen generation unit according to the separate operating instructions. Switch off the Airmould pressure generation unit according to the separate operating manual. 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 to proper equipment for protection against falling down must be worn! 4 Move the climbing aid in front of the machine. 5 Move the "Material hopper" away from the "Screw Barrel" feed zone. 6 Heat the "Screw barrel" heating to the operating temperature that was set last. 7 Press the "Injection unit back" key until there is enough room to purge the remaining moulding compound. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! 8 Open the "Protective guard" of the "Nozzle". 9 Place a suitable container in front of the "Nozzle". Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! Chapter VMRGB0LA 0914TW

109 10 Close the "Protective guard" of the "Nozzle". 11 Eject the residual moulding compound at short intervals. 12 Purge the screw barrel with an appropriate cleaning material. Consult your plastics manufacturer about the suitable material. 13 Switch off water system, pneumatic system, modular Airmould system (option). See also the paragraph "Shutting down the machine" (chapter "Operation"). Only for Airmould nozzle: If the nitrogen system is not relieved from pressure before starting work, it may lead to an explosive loss of pressure with risks of damage and injury! For Airmould nozzle: ( ) Relieve the "Modular Airmould system" from pressure. For the procedure see the operating manual "Modular Airmould system" (chapter "Transport - installation", paragraph "Preparation for no-load mode and interlock test without material"). ( ) Switch off the main switch at the "Modular Airmould system" and secure against unintentional reconnection. 14 Switch off the heating of "Nozzle" and "Screw barrel". 15 Block hydraulic system. 16 Switch off the main switch and use a padlock to prevent accidental reconnection. The main switch should be operated whenever possible without applied load. 17 Open the "Protective guard" of the "Nozzle". Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The nozzle may only be dismantled and mounted by an authorised skilled technician! 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 to proper equipment for protection against falling down must be worn! ATTENTION Only use tools and support equipment that will not damage the assembly components! The remaining procedure is described in the following chapters depending on the nozzle type VMRGB0LA 0914TW Chapter 6.2-7

110 Changing "open nozzles Figure 1 Open nozzle Figure 2 Open Airmould nozzle, pressure-controlled Basic requirement paragraph 1-20 (chapter ) 1 Dismantle the heater band of the "Nozzle" (1). 2 Position a hexagon spanner on the "Hexagon" (3) and unscrew the "Nozzle" (2). Only for Airmould nozzle: Unscrew the "Union nut" (B) of the "Nitrogen pressure line" (A) at the "Nozzle body". 3 Position a hexagon spanner on the "Hexagon" and unscrew the "Nozzle body". Fire hazard! Use no flammable solvents! 4 Thoroughly clean the "Nozzle" and the "Nozzle body". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Chapter VMRGB0LA 0914TW

111 5 Lubricate the thread of the new or cleaned "Nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and wear before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). 6 Screw the "Nozzle body" home by hand but do not fi nally tighten. 7 Screw the "Nozzle" home by hand but do not fi nally tighten. 8 Mount the heater band of the "Nozzle". 9 Switch on main switch. 10 Switch on hydraulics ("Hydraulics Start" key). 11 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 12 Tightly screw in the "Nozzle and "Nozzle body after heating to operating temperature. Torque settings see chapter "Technical data. Only for Airmould nozzle: Screw in the "Union nut" of the "Nitrogen pressure line" at the "Nozzle body" until there is a signifi cant increase in force detectable. Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! 13 Close the "Protective guard of the "Nozzle. Only for Airmould nozzle: Switch on the main switch at the control cabinet of the "Modular Airmould system". Pressurize the "Nitrogen pressure line" and check the "Union nut" for leaks. For the procedure see the operating instructions "Modular Airmould system" (chapter "Maintenance") paragraph "Nitrogen leakages". VMRGB0LA 0914TW Chapter 6.2-9

112 Replacing the "Herzog" needle shut-off nozzle of type SHP, spring-controlled Body 2 Needle guide bush 3 Fixing pin 4 Thrust ring 5 Spring assembly 6 Adaptor 7 Shut-off needle 8 Nozzle head 9 Heater band 10 Temperature probe Chapter VMRGB0LA 0914TW

113 Basic requirement paragraph 1-20 (chapter ) 1 If necessary, unscrew "Temperature probe" (10) 2 Dismantle the heater band of the nozzle (9) 3 Screw out the nozzle head (8) 4 Withdraw the shut-off needle (7) 5 Screw off the "Adaptor" (6) Fire hazard! Use no flammable solvents! 6 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 7 Greasing these components will cause impurities to the melt. Lubricate all threads of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). VMRGB0LA 0914TW Chapter

114 8 Mount the needle valve nozzle in reverse order 9 Screw the adaptor (6) home by hand but do not fi nally tighten 10 Insert the shut-off needle (7) 11 Screw the nozzle head (8) home by hand but do not fi nally tighten 12 Mount the heater band (9) of the nozzle 13 If necessary, screw the temperature probe (10) home by hand but do not fi nally tighten 14 Switch on main switch. 15 Switch on hydraulics ("Hydraulics Start" key). 16 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 17 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature. Tightening torque: "Nozzle head" (8) Nm (162 ft lb). "Fixing pin" (3) - 3 Nm (2 ft lb). "Body " (1) Nm (125 ft lb). "Adaptor" (7) - see the "Technical Data" chapter. Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! 18 Close the "Protective guard" of the "Nozzle". Chapter VMRGB0LA 0914TW

115 Changing the "Fuchslocher needle valve nozzle Nozzle body 2 Spring chamber 3 Compression spring 4 Heater band 5 Shut-off needle 6 Nozzle head Basic requirement paragraph 1-20 (chapter ) 1 Screw out the temperature probe 2 Dismantle the heater band (4 from the nozzle head (6). 3 Position a hexagon spanner on the "Hexagon" and unscrew the nozzle body (1). The "Spring chamber" (2) must not be dismantled. We can accept no responsibility for damage resulting from improper handling! If the needle valve nozzle does not function any more, please contact our Customer Service. The addresses can be found in the "Customer service" chapter. VMRGB0LA 0914TW Chapter

116 Fire hazard! Use no flammable solvents! 4 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 5 Greasing these components will cause impurities to the melt. Lubricate all thread of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). 6 Screw the nozzle body (1) home by hand but do not fi nally tighten. 7 Mount the heater band (4) of the "Nozzle". 8 Screw in the temperature probe. 9 Switch on main switch. 10 Switch on hydraulics ("Hydraulics Start" key). 11 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Chapter VMRGB0LA 0914TW

117 Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 12 Tightly screw in the "Nozzle" and "Nozzle body" after heating to operating temperature. Torque setting: 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 pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! 13 Close the "Protective guard" of the "Nozzle". VMRGB0LA 0914TW Chapter

118 Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP, with integrated control cylinder Nozzle head 2 Shut-off needle 3 Fixing pin 4 Lever bolt 5 Lever 6 Screws 7 heater band 8 Temperature probe 9 Adaptor 10 Yoke / adaptor ring 11 Control cylinder Chapter VMRGB0LA 0914TW

119 Basic requirement paragraph 1-20 (chapter ) 1 If necessary, unscrew temperature probe (8). 2 Dismantle the heater band (7) of the nozzle. 3 Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from the control cylinder (11) and remove the lever (5). 4 Screw out the nozzle head (1). 5 Withdraw the shut-off needle (2). 6 Screw off the adaptor (9). Fire hazard! Use no flammable solvents! 7 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 8 Greasing these components will cause impurities to the melt. Lubricate all thread of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). VMRGB0LA 0914TW Chapter

120 9 Mount the needle valve nozzle in reverse order. 10 Screw the adaptor (9) home by hand but do not fi nally tighten. 11 Insert the shut-off needle (2). 12 Screw the nozzle head (1) home by hand but do not fi nally tighten. 13 Mount the heater band (7) of the nozzle. 14 If necessary, screw the temperature probe (8) home by hand but do not fi nally tighten. 15 If the control cylinder (11) did not reach the wished position after having screwed it in (e.g. control cylinder (11) faxing vertically up), the 12 screws (6) must be screwed out by 4 turns and then the position of the control cylinder (11) can be changed clockwise. 16 Tighten 2 screws (6) crosswise, check the gap between body and adaptor ring up to a 7 6 Turn clockwise 1 maximum of 2.5 mm (0.1 inch) Chapter VMRGB0LA 0914TW

121 17 Tighten all screws crosswise 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 pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the control cylinder (12) and mount the lever (5). 19 Switch on main switch. 20 Switch on hydraulics ("Hydraulics Start" key). 21 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 22 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature. Tightening torque: 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 pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! VMRGB0LA 0914TW Chapter

122 Replacing the pneumatically triggered "Herzog bolt valve nozzle, type HP, with integrated control cylinder Nozzle head 2 Bolt lock 3 Lever bolt 4 Lever 5 Screws 6 Heater band 7 Temperature probe 8 Adaptor 9 Yoke / adaptor ring 10 Control cylinder 11 Shut-off nut 12 Body Chapter VMRGB0LA 0914TW

123 Basic requirement paragraph 1-20 (chapter ) 1 If necessary, unscrew temperature probe (7). 2 Dismantle the heater band (6) of the nozzle. 3 Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from the control cylinder (10) and remove the lever (4). 4 Screw out the nozzle head (1). 5 Screw off the adaptor (8). 6 Screw out the shut-off nut (11). 7 Remove the bolt lock (2). Sometimes, the removal of bolt and bolt bushing might be a problem Do not exercise too much force on this part. If you have problems during removal, please contact the Herzog company. Use a mandrel to carefully knock up the bolt. Remove bushing and bolt from above. The grooves on the bolt bushing must be aligned on the body by means of the positioning pin. VMRGB0LA 0914TW Chapter

124 Fire hazard! Use no flammable solvents! 8 Thoroughly clean the components of the "Nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 9 Greasing these components will cause impurities to the melt. Lubricate all thread of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). 10 Mount the bolte valve nozzle in reverse order. 11 Screw the adaptor (8) home by hand but do not fi nally tighten. 12 Push in the bolt lock (2) and screw in the shut-off nut (11). 13 Screw the nozzle head (1) home by hand but do not fi nally tighten. 14 Mount the heater band (6) of the nozzle. 15 If necessary, screw the temperature probe (7) home by hand but do not finally tighten. 16 Connect pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the control cylinder (10). Chapter VMRGB0LA 0914TW

125 17 Switch on main switch. 18 Switch on hydraulics ("Hydraulics Start" key). 19 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 20 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature. Tightening torque: 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 pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! VMRGB0LA 0914TW Chapter

126 Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP 1 Adaptor 2 Temperature probe 3 Heater band 4 Nozzle head 5 Screws 6 Rod assembly Basic requirement paragraph 1-20 (chapter ) 1 If necessary, unscrew temperature probe (2). 2 Dismantle the rod assembly (6). 3 Dismantle the heater band (3) of the nozzle. 4 Screw out the nozzle head (4). 5 Withdraw the shut-off needle. 6 Screw off the adaptor (1). Chapter VMRGB0LA 0914TW

127 Fire hazard! Use no flammable solvents! 7 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 8 Greasing these components will cause impurities to the melt. Lubricate all threads of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). 9 Mount the needle valve nozzle in reverse order. 10 Screw the adaptor (10) home by hand but do not fi nally tighten. 11 Insert the shut-off needle (2). 12 Screw the head (1) home by hand but do not fi nally tighten. 13 Mount the heater band (8) of the nozzle. 14 If necessary, screw the temperature probe (9) home by hand but do not fi nally tighten. VMRGB0LA 0914TW Chapter

128 15 Switch on main switch. 16 Switch on hydraulics ("Hydraulics Start" key). 17 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 18 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature. Tightening torque: 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 Assemble the rod assembly (6). 20 Close the "Protective guard" of the "Nozzle". Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! Chapter VMRGB0LA 0914TW

129 The nozzle is delivered as sub-assemblies. The final assembly is made on the machine After having aligned the rod assembly with the nozzle, the fl ange bolts can be tightened crosswise in four steps. The gap between body and adaptor ring can change between 0.5 and2.5 mm (0.02 and 0.1 inch). Gap between body and adaptor ring Flange bolts Rod assembly Tighten the screws crosswise Step 1 = prefi x all screws evenly Step 2 = 70 % of the tightening torque Step 3 = 90 % of the tightening torque Step 4 = tighten with 12 Nm (9 ft lb) VMRGB0LA 0914TW Chapter

130 Replacing the pneumatically or hydraulically triggered "Fuchslocher" needle valve nozzle Nozzle body 2 Thrust ring 3 Heater band 4 Nozzle head 5 Shut-off needle 6 Fork Basic requirement paragraph 1-20 (chapter ) 1 If necessary, unscrew temperature probe. 2 Dismantle the heater band (3). 3 Dismantle the rod assembly from the fork (6). 4 Screw out the nozzle head (4). 5 Withdraw the shut-off needle (5). 6 Screw out the nozzle body (1). Chapter VMRGB0LA 0914TW

131 Fire hazard! Use no flammable solvents! 7 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 8 Greasing these components will cause impurities to the melt. Lubricate all threads of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). 9 Mount the needle valve nozzle in reverse order. 10 Screw the nozzle body (1) home by hand but do not fi nally tighten. 11 Insert the shut-off needle (5). 12 Screw the nozzle head (4) home by hand but do not fi nally tighten. 13 Mount the heater band (3) of the nozzle. 14 If necessary, screw the temperature probe home by hand but do not fi nally tighten. VMRGB0LA 0914TW Chapter

132 15 Switch on main switch. 16 Switch on hydraulics ("Hydraulics Start" key). 17 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 18 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature. Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! 19 Close the "Protective guard" of the "Nozzle". Chapter VMRGB0LA 0914TW

133 ENG pneumatic needle valve nozzle with integrated control cylinder Nozzle body 2 Control cylinder 3 Rod assembly 4 Nozzle head 5 Body 6 Tension nut Basic requirement paragraph 1-20 (chapter ) 1 If necessary, unscrew temperature probe. 2 Dismantle the heater band. 3 Dismantle the rod assembly (3). 4 Screw out the nozzle head (4). 5 Withdraw the shut-off needle. 6 Screw out the nozzle body (1). VMRGB0LA 0914TW Chapter

134 Fire hazard! Use no flammable solvents! 7 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 8 Greasing these components will cause impurities to the melt. Lubricate all thread of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heatresistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle"). 9 Mount the needle valve nozzle in reverse order. 10 Screw the nozzle body (1) home by hand but do not fi nally tighten. 11 Insert the shut-off needle. 12 Screw the nozzle head (4) home by hand but do not fi nally tighten. 13 Mount the heater band of the nozzle. 14 If necessary, screw the temperature probe home by hand but do not fi nally tighten. Chapter VMRGB0LA 0914TW

135 15 Switch on main switch. 16 Switch on hydraulics ("Hydraulics Start" key). 17 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying out! 18 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature. Tightening torque: "Tension nut" (6) "Nozzle head (4) L Nm (443 ft lb). L Nm (885 ft lb). L Nm (184 ft lb). L Nm (443 ft lb). Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard! 19 Close the "Protective guard" of the "Nozzle". VMRGB0LA 0914TW Chapter

136 6.2.5 Dismantling the screw barrel / screw Dismantling the screw up to size Dismantle the "Nozzle" as described in the paragraph "Dismantling the nozzle". 2 Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical stop. 3 Open the "Safety gate on the operator and rear side. 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 to proper equipment for protection against falling down must be worn! 4 Unscrew the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen". 5 Press the "Injection unit forward" key. The "Piston rods" of the "Nozzle contact cylinders" are moved in. 6 Switch off hydraulics ("Hydraulics stop" key). 7 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 VMRGB0LA 0914TW

137 8 Dismantle the cover of the "Guarding" of the "Injection cylinder". ATTENTION Only use tools and aids which do neither damage the nozzle nor its components described below! 9 Slightly unscrew the "Screws" (1) of the "Clamping disc" (2) and remove the two "Wedges" (3). 10 Slightly loosen but do not unscrew the "Clamping bolt". 11 Swivel out the "Injection unit" in the direction of the operator side. 12 Dismantle "Nozzle" and / or "Nozzle head" as described in this chapter. VMRGB0LA 0914TW Chapter

138 13 Secure the "Screw" with a corresponding aid and pull it out of the "Screw barrel" to the front. For the weight of the "Screw", see the "Technical data" chapter. 14 If necessary, unscrew the "Screw tip" as described in this chapter. Danger of injury and damaging components! Only parts (nozzle, screw, barrel and its fixing screws) supplied or specified by Battenfeld may be used! 15 Clean the "Screw" and the "Screw tip" or mount a new "Screw" and "Screw tip". - Coat all threads with a temperature resistant Molykote. - Check the contact surfaces for damage and the individual components for wear and function before mounting. The "Screw" is always mounted in reverse order as described in this chapter. Chapter VMRGB0LA 0914TW

139 Retooling for a different screw diameter up to size 1330 Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! 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 to proper equipment for protection against falling down must be worn! Coat all threads with a high-capacity assembly paste. It must be water-repellent, corrosionproof, material-indifferent, and heat-resistent (at least up to 350 C / 662 F). Check the contact surfaces for damage and the individual components for wear and function before mounting. 1 Dismantle "Screw" and "Screw barrel" as described in this chapter. 2 Cover the entire mating surface of the new "Screw barrel" with a "Heat-resistant Molykote". 3 Mount the new "Screw barrel" as described in this chapter. 4 Mount the "Screw tip" as described in this chapter. 5 Insert the new "Screw" into the "Screw barrel" until the "Screw shaft" is located in front of the "Thrust piece". VMRGB0LA 0914TW Chapter

140 6 With a "Screw" with a smaller diameter, mount the supplied "Sleeve" onto the "Screw shaft" (push on). 7 Push the "Screw shaft" into the "Thrust piece" to the stop. 8 Adjust the "Screw shaft" so that the "Wedges" can engage in the cut. 9 Insert the new "Wedges" (3) into the recess of the "Thrust piece". 10 Screw the "Screws" (1) of the "Clamping disc" (2). The torque settings for the "Bolts" are detailed in the chapter "Technical Data". 11 Mount the "Nozzle" as described in the pargraph "Dismantling the nozzle". 12 Label the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" in such a manner that if is unmistakably assigned to the corresponding "Screw barrel". Chapter VMRGB0LA 0914TW

141 13 Dismantle the "Extension" of the "Piston rod" of the "Nozzle contact cylinders". 14 Mount the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" for the current "Screw barrel". The key surface (1) must be vertically positioned to ensure proper closing and opening of the purge guard. The torque settings for the "Bolts" are detailed in the chapter "Technical Data" Fit the "Heater bands" hand-tight to the "Screw barrel" and mount the "Material hopper feed throat" if necessary. 16 Displace the "Guarding" with the stroke measuring system of the "Nozzle". If the new "Screw barrel" is larger than the old one, move the stroke measuring system to the right, away from the "Nozzle platen". 17 Mount the "Nozzle" and / or "Nozzle head" as described in this chapter. 18 Swivel the "Injection unit" in towards the "Nozzle platen". 19 Screw in the "Clamping bolt". The torque settings for the "Bolts" are detailed in the chapter "Technical Data". 20 Install the cover of the "Guarding" of the "Injection cylinder". 21 Prepare the machine as described in the "Operation" chapter in the paragraph "Test run without material". 22 Press the "Setting mode" key. 23 Press the "Injection unit back" key. The "Piston rods" of the "Nozzle contact cylinders" are moved out. 24 Open the "Safety gate" on the operator and rear side. VMRGB0LA 0914TW Chapter

142 25 Scre in the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen". 26 Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical stop. 27 Mount the "Nozzle" in reverse order as described in the paragraph "Dismantling the nozzle". 28 Recalibrate the stroke measuring system of the "Nozzle" (see "User manual"). 29 Check the nozzle centring as described in chapter "6.2.3 Levelling the machine" Dismantling the screw tip 1 Dismantle "Nozzle" and / or "Nozzle head" as described in this chapter. 2 Dismantle the "Screw" as described in this chapter. ATTENTION Left hand thread! When removing or changing the screw tip it should be noted that the screw tip is fitted to the screw with a left-hand thread! 3 Screw out the "Screw tip" using a special tool (option). "Screw tip" with "Back fl ow check with ring". Chapter VMRGB0LA 0914TW

143 "Screw tip" with "Back fl ow check with ring". Fire hazard! Use no flammable solvents! 4 Thoroughly clean the components of the "Screw tip. Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components. The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles. Danger of injury and damaging components! Only components that were either supplied or specified by Battenfeld should be implemented! ATTENTION Do not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt! 5 Greasing these components will cause impurities to the melt. Lubricate all threads of the new or cleaned "Screw tip" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 C / 662 F). VMRGB0LA 0914TW Chapter

144 6.2.6 Cleaning the barrel, material changes The increasing requirements for quality fi nished plastic articles necessitate the frequent and thorough cleaning of all components which come into contact with plastics Purging out with virgin polyethylene This process ensures an almost total purging of the previous material. However the polyethylene must in turn be forced out of the screw and barrel by the new material. It is not usually necessary to clean the screw by hand Purging out with a barrel purging agent. The purging compount is usually a colourless, high molecular weight, thermoplastic material which at approx. 100 C (212 F) is viscoelastic, but does not fl ow, melt or stick. In the form of an elastic plug, it pushes the previous material from the screw barrel. Usually, it is not necessary to clean the screw by hand. Before cleaning shut-off nozzles and open nozzles must be removed and the nozzle temperature lowered. The temperature of the screw barrel should stay below (below 300 C / 572 F), injection pressure should be set to minimum or slightly above if required Cleaning the screw barrel ATTENTION The screw must never be cleaned with a gas burner, a sand blast system or by glowing out! These methods result in the loss of the mechanical and technological characteristics of the screw. In such a case, all warranty claims expire. The screw must be cleaned with a brass brush only. Using a wire brush can damage the surface. We also recommend the use of a blast system with thermoset particles. The barrel is cleaned with a rotating brass brush mounted to a long rod; a hand-held electric drill or similar device can be used to drive it Storage When storing the barrel it has been found effective to fi ll the barrel with about (200 g / 7 oz) of silica gel or similar desiccant and seal the openings. The screws should be kept in plastic sleeves, also containing silica gel. This will largely prevent corrosion. Chapter VMRGB0LA 0914TW

145 6.3 Hydraulics General information Pump unit The IMM hydraulic system has a number of benefi cial features: Easily accessible hydraulic system. Energy saving pump with electric adjustment enables smooth movements with high precision and extremely short dry cycle times. The hydraulic components are arranged so that pipes and hoses are reduced to a minimum. Maintenance-friendly construction. Full fl ow fi ltration keeps the oil quality high for long periods. The pump unit comprises an electric motor, pump carrier, pump carrier support, coupling, and the variable capacity pump. The pump unit is mounted on anti-vibration mounts inside the machine frame under the injection unit. A compressed oil line connects the pump unit with the pump block. The leak oil line as well as a vacuum oil line lead to the oil tank. There is no way of closing the line between hydraulic tank and pump unit Hydraulic tank The hydraulic tank is a fi xed part of the machine frame and is equipped with a fi ller cap with strainer, venting fi lters, and an oil level indicator with electrical monitoring and a temperature sensor. The oil tank may only be fi lled through the strainer of the fi ller cap. This can be found within the machine frame close to the end platen. The oil, of cleanliness class 17/15/12 acc. to ISO 4406 (Class 6 acc. to NAS 1638), must be prefi ltered through a mobile fi ltration unit fi tted with a 3 μm mesh fi lter. The hydraulic tank is equipped with connectors for an external oil fi ltration unit. The tank cover has to be removed for cleaning the hydraulic tank. HM6GB0MA 0914TW Chapter 6.3-1

146 6.3.4 Pressure filter To improve the reliability and longevity of the hydraulic components and seals, a non-bypass pressure fi lter (fi lter mesh 5 μm absolute) is provided in the main pressure line of the hydraulic system. The pressure fi lter is fl anged to the pump block and can be accessed from outside. The pressure fi lter has an electrical clogging monitor which sends a warning message to the control screen if it is triggered. If this message has not disappeared by the time the oil has reached its preheating temperature, the fi lter element must be replaced at once. CAUTION To ensure trouble-free operation and long service life of the hydraulic components, only original filter elements may be used! Oil cooler In the oil cooler, cooling water is directed through the cooling lines which are surrounded by hydraulic oil, so that at the appropriate water fl ow rate and temperature adequate cooling of the hydraulic oil can be ensured. It is essential to ensure that the water used is maintained at the quality detailed in "Maintenance" chapter. Otherwise a water fi lter (option) must be fi tted in the supply to protect the operation of the cooling water shutoff valve. This regulates the cooling water fl ow and maintains a constant oil temperature by opening and closing the water supply as appropriate Control and display The oil temperature is measured in the oil tank. This temperature is indicated on the screen of the machine control unit to the operating personnel. Chapter HM6GB0MA 0914TW

147 6.3.7 Pressure setting The electrically adjustable pump takes care of the hydraulic pressure setting for all functions. The electrical pump control is effected by entering the corresponding pressure for each function on the control screen. Pressures are entered in "bar" (psi) Speed setting The electrically adjustable pump takes care of the hydraulic speed setting for all functions. The electrical pump control is effected by entering the corresponding speed for each function on the control screen. Speeds are entered as absolute values (mm/sec, inch/sec) Hydraulic oil preheating As soon as the hydraulic pump is started the cold hydraulic oil is automatically preheated to a temperature of 40 C (104 F) (with ServoPower (Option) 30 C (86 F)). While the oil temperature is below this value, the screen shows an error message and the IMM can not be moved. After reaching the 40 C (104 F) (with ServoPower (Option) 30 C (86 F)) mark, the oil preheating switches off and the IMM is ready for operation. While the IMM is running, the oil temperature is regulated to a constant 45 C (113 F) (with ServoPower (Option) 35 C (95 F)). This is achieved by opening and closing the cooling water valve on the oil cooler. If the oil temperature exceeds 60 C (140 F) (with ServoPower (Option) 50 C (122 F)) an error message is shown on the screen. If the temperature exceeds 65 C (149 F) (with ServoPower (Option) 55 C (131 F)), the control switches the IMM hydraulics off. The reason for the oil s overheating must be established and the fault remedied (e.g. water supply failure, cooling water shut-off valve on oil cooler closed.) After operating the emergency stop button once, the hydraulics can be restarted. In this way, the hydraulic oil is cooled. No movements (from the clamping and injection unit) are possible during this phase. HM6GB0MA 0914TW Chapter 6.3-3

148 Hydraulic core puller The hydraulic core puller (option) consists of a base plate on which the required hydraulic valves are installed and which includes the user connections (NW 6 or NW 10). This function module is mounted on the clamping block or pump block. The hose assemblies and fi ttings belonging to the mould s core puller cylinder are not included in the delivery. It should also be noted that the maximum system pressure is 250 bar (3625 psi). All connections and fi ttings must be able to withstand this pressure! Hydraulic core pullers may be connected and put into operation only by a hydraulics expert. The safety regulations in the "Safety" chapter are to be followed without fail! Chapter HM6GB0MA 0914TW

149 6.4 Pneumatics UNIFEED material feeder Area of Applicability The UNIFEED material feeder (option) was designed for use on plastics processing machinery and is installed directly on the feed throat instead of the hopper. The material feeder is highly reliable as it has no moving parts and it is easy both to use and to service. The following granular polymers can be conveyed by UNIFEED: PE-HD, PE-LD, PS, PA, PA + GF, PP, ABS, POM, PPO. VMRGB0NA 0814TW Chapter 6.4-1

150 Structure and function If the material level falls below the capacitive proximity switch (6) during metering, the pneumatic valve (2) opens. Compressed air is blown into the venturi tube (11) through the air jet (9) generating a partial vacuum which extends as far as the suction chamber (10) and the feed tube (4). This vacuum sucks a granule - air mixture through the suction tube (5) and connecting hose (1) into the feed tube (4). A primary fi lter (8) separates the granules from the conveying air. Dust is then removed from the conveying air in the secondary fi lter (12) before the is vented from the material feeder. When the material level once again reaches the capacitive proximity switch, the air valve is closed, the air fl ow stops and the conveying cycle is fi nished. At the end of every conveying cycle a small volume of compressed air is fed in pulses to the suction chamber (10), thereby cleaning the material dust automatically from the primary fi lter. Processing regrindthe UNIFEED material feeder is well suited to conveying regrind and virgin materials together. The particle size must no be larger than 3-4 mm ( inch). The higher proportion of dust will lead to heavier loading of the fi lter, so that shorter cleaning intervals must be allowed for Pneumatic core puller The pneumatic core puller (option) comprises an electrically actuated 5/2 pneumatic valve and all the consumer connections for a 6 mm (0.24 inch) bore plastic pipe. This function module is mounted onto the central console or on the media block of the clamping platen. The connection to the mould s core puller cylinder is not supplied with the IMM. ATTENTION It should be noted that the compressed air used should be dried and lubricated and limited to a pressure of 6 bar (87 psi). All connections and fittings must be able to withstand this pressure! Chapter VMRGB0NA 0814TW

151 6.4.3 Air supply unit The air supply unit (option for all pneumatic consumers) cleans the resource compressed air from liquid and solid matter and controls the air pressure Setting knob pressure control valve 2 Condensate separator 3 Pressure gauge 4 Condensate reservoir 5 Drain screw The air supply unit should be used only with properly processed compressed air without any aggressive components. A fi lter with a water trap separates the compressed air from solid contaminants and water. This protects the pneumatic components fed by it from premature wear. VMRGB0NA 0814TW Chapter 6.4-3

152 Chapter VMRGB0NA 0814TW

153 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 defi ning feature of gas injection is the fi lling of the mould cavity with two fl uids. One fl uid 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 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. EWAGB0OB 0814TW Chapter 6.5-1

154 The main parts of the pressure generator 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 EWAGB0OB 0814TW

155 6.6 Electrics Electric drive Three phase asynchronous motor The pump unit is driven by a three phase asynchronous motor. The drive motor is coupled directly to the hydraulic pump and connected to suit the operating voltage. When connected correctly (the phase sequence must give a righthand fi eld, see "Transport - Installation" section) the drive motor will run left (counterclockwise) seen from the D-end. D - End: Drive end. N - End: Non-drive end (fan end). Service and connection work on the terminal rail may only be carried out by an authorised electrician! Speed-controlled servo motor The pump unit is driven by a speed-controlled servo motor. The drive motor is coupled directly to the hydraulic pump and connected to suit the operating voltage. Service and connection work on the terminal rail may only be carried out by an authorised electrician! VMRGB0PA 0814TW Chapter 6.6-1

156 6.6.2 Switch cabinet The electrical cabinet is easily accessed on the rear side of the IMM and contains most of the electrical components necessary for operation. 1 Main switch 2 Door latch 3 Mounting plate, sockets 4 Main supply Chapter VMRGB0PA 0814TW

157 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 Operator 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 1 Ethernet interfaces) are located at the rear side in the switch cabinet. EWAGB0QC 1214MC Chapter 6.7-1

158 6.7.3 Explanation of the picture Flexibility UNILOG B6 is a control concept which meets all demands concerning fl exibility. With the free core puller programming, the user can, for example, quickly and fl exibly 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 EWAGB0QC 1214MC

159 Holding pressure The combination of tabular input and graphic represenation facilitates the setting of the machine with the number of profi le 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, 3 confi gurable 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. EWAGB0QC 1214MC Chapter 6.7-3

160 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 EWAGB0QC 1214MC

161 Cycle time analysis Analysis at a glance. The confi gurable 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. EWAGB0QC 1214MC Chapter 6.7-5

162 Alarm system The production process can be backtraced by means of a comprehensive alarm / logging concept with different fi ltering 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 Windows TM by means of 2 USB interfaces located laterally on the operator panel and 2 other USB interfaces in the switch cabinet. Ethernet interfaces 1 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 EWAGB0QC 1214MC

163 6.7.5 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 / EPL connection X2X I/O system EWAGB0QC 1214MC Chapter 6.7-7

164 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 EWAGB0QC 1214MC

165 Automation panel link plug-in module SDL The automation panel link plug-in module is the interface between an automation PC and an automation panel 9xx. Graphic signals of an industrial PC (e.g. automation PC 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). By means of simple slide-in technique, this plug-in module is plugged into the slide-in slot of the automation panel 900 and fi xed to the automation panel by means of the two fi xing screws (max. tightening torque 0.5 Nm). Fixing screws Display cable SDL cable 5CASDL.0xxx-00 Voltage supply +24VDC In Panel IN (via SDL) ATTENTION 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. The SDL cable may be connected and disconnected in the dead state only. Pin assignment Casing Casing EWAGB0QC 1214MC Chapter 6.7-9

166 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 VDC Bus interface: 2 x Ethernet Powerlink (EPL) Chapter EWAGB0QC 1214MC

167 Automation PC The Automation PC with Intel Core i technology 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 Interface Option 2 Monitor / panel / interface Interface Option 1 Voltage supply or status LEDs: * Depending on the bus type used: EWAGB0QC 1214MC Chapter

168 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%). status LEDs: Power key Reset key Battery Chapter EWAGB0QC 1214MC

169 I/O modules Three basic elements form a single module: Bus module - electronic module - fi eld 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 fi eld 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 EWAGB0QC 1214MC Chapter

170 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. Alternativ zu X20BR9300 -> X20BC0083/X20PS9400 X20BC0083 The BC0083 Bus Controller enables the connection of X2X Link I/O nodes (modules) to POWERLINK (standard protocol for Fast Ethernet). X20PS9400 The PS9400 supply module is used together with an X20 Bus Controller (e.g. X20BC0083). It is equipped with a supply for the Bus Controller, the X2X Link and the 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 VDC) with the aid of different connection terminals. Chapter EWAGB0QC 1214MC

171 X20AO4632 The module AO4632 has four outputs with 16-bit digital converter resolution. It can be switched between current and voltage signal (+/- 10 VDC) with the aid of different connection terminals. X20AT6402 The module AT6402 has six inputs for J, K, N and S thermocouple sensors. A terminal temperature compensation is integrated in the module. X20PS4951 The module PS4951 has four +/-10 VDC voltage supply channels for the potentiometer supply. CS 1070 The CS 1070 module is equipped with a CAN bus interface. Furthermore, an additionally connectable terminating resistor is included. CS 2770 The CS 1070 module is equipped with 2 CAN bus interfaces. Furthermore, an additionally connectable terminating resistor is included. EWAGB0QC 1214MC Chapter

172 Chapter EWAGB0QC 1214MC

173 7 Operation 7.1 Miscellaneous 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 fi elds will still be present after switching off the machine at the main switch. Only after demagnetising the magnetic modules will the magnetic fi elds be neutralised, i.e. the hazard will no longer be present. ATTENTION 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. ATTENTION 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! VMRGB0RB 0914TW Chapter 7-1

174 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 fi rst start-up and, if necessary, oil must be fi lled in or refi lled 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 VMRGB0RB 0914TW

175 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 refi lled. 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 refi ll, reduce and check the nitrogen pressure, please refer to the "Transport - Installation" chapter. 1 Check at least once within the fi rst 40 operating hours. Major losses in nitrogen will immediately be detected and be compensated. 2 In case no losses have been detected during the fi rst 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. VMRGB0RB 0914TW Chapter 7-3

176 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 fl ow 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 fi ltration unit (option). Chapter 7-4 VMRGB0RB 0914TW

177 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! VMRGB0RB 0914TW Chapter 7-5

178 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 Core puller out (option) Chapter 7-6 VMRGB0RB 0914TW

179 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 fi rst 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. VMRGB0RB 0914TW Chapter 7-7

180 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! ATTENTION 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 VMRGB0RB 0914TW

181 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 profi le (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. VMRGB0RB 0914TW Chapter 7-9

182 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 ATTENTION 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 fi nish your work at the control unit, you will have to logout fi rst. 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 VMRGB0RB 0914TW

183 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 fi rst 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 fi t 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 fi rst 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. VMRGB0RB 0914TW Chapter 7-11

184 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 VMRGB0RB 0914TW

185 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 fi ll 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) defl ate 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 VMRGB0RB 0914TW Chapter 7-13

186 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! 1.1 Let the mould cool down to a safe temperature (material dependent). 1.2 Prepare the mould for dismantling (Disconnect cooling hoses, heating cables etc.). Burning hazard if touched! At mould temperatures above 60 C (60,00 C) wear appropriate PPE! 2 Loosen the upper part (mould clamps, quick-action mould mounting system) 3 Mount the safety strap holding the two mould halves together. 4 Turn the rotary table from station A (injection station) into station C (operator station). 5 Turn the rotary table (in the setting mode) until the ejector coupling has been released. Disconnect the ejector coupling (mould to hydraulic ejector cylinder). 6 Loosen the lower part (mould clamps, quick-action mould mounting system) The safe working load of the lifting equipment must equal or exceed the weight of the mould! 7 Mount the lifting gear at the mould. Chapter 7-14 VMRGB0RB 0914TW

187 Danger of death! It must be ensured that no persons stand or linger under the suspended load! 8 Lift the mould horizontally out of the opened clamping unit. 9 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 fl ow 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. VMRGB0RB 0914TW Chapter 7-15

188 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) defl ate 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 fi lter. 3 Thoroughly clean the area around the fi ller and screw plugs on the transport and storage containers. 4 Unscrew the venting fi lter lock and remove the complete venting fi lter 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" chapter). Chapter 7-16 VMRGB0RB 0914TW

189 6 Place the venting fi lter on the pipe socket again. 7 Remove the tank cover and clean the hydraulic tank 8 Remove the housing of the hydraulic fi lter. Dispose of the liquid in a suitable container, see chapter "Maintenance", "Hydraulic fi lter" 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! VMRGB0RB 0914TW Chapter 7-17

190 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 2 Cut off the water supply (1) to the cooling water fl ow control Turn the two hand-wheels (2+3) of the cooling water fl ow control counterclockwise (Close cooling water fl ow). 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 fl ow control and drain the cooling water to appropriate systems or containers. 7 Disconnect the cooling water fl ow (1) from the cooling water fl ow control and drain the cooling water to appropriate systems or containers. 8 Turn both hand-wheels (2+3) of the cooling water fl ow control cw (Open cooling water fl ow) and drain the cooling water to appropriate systems or containers 9 Disconnect the cooling water fl ow 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 fl ow 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 fi ttings of the supply and return lines to protect them against contamination 6 Chapter 7-18 VMRGB0RB 0914TW

191 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. VMRGB0RB 0914TW Chapter 7-19

192 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 fi lled with hydraulic oil; see chapter "Transport - Installation". 4 Replace the "Hydraulic fi lter" and "Venting fi lter" fi lter 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" Chapter 7-20 VMRGB0RB 0914TW

193 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 fi lled and fl ushed 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 fl ushing, the machine should be refi lled 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. VMRGB0RB 0914TW Chapter 7-21

194 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" Chapter 7-22 VMRGB0RB 0914TW

195 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. VMRGB0RB 0914TW Chapter 7-23

196 Chapter 7-24 VMRGB0RB 0914TW

197 8 Maintenance 8.1 Miscellaneous Careful installation and care are necessary for the reliable functioning of the injection moulding machine (hereinafter machine). Daily visual checks help to prevent down times. Checks, maintenance work and the exchange of worn out parts should be undertaken at regular intervals. Only parts of the same quality (strength, material) and design may be used. Breakdowns of the machine caused by inadequate or improper maintenance can result in very high repair costs and long periods of down time. Regular maintenance is therefore essential. If you have questions about maintenance or service of the machine, please contact our Technical Service Department or one of our subsidiaries. The addresses can be found in the "Customer service" chapter. The safety regulations in the "Safety" chapter are to be followed without fail! Before starting any maintenance or repair work the main switch of the machine must be switched off and secured against accidental reconnection! 8.2 Transport, storage and disposal of lubricants 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 fi elds 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 notifi ed immediately. The amount of lubricant discharged before notifi cation 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 suffi cient 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. VMRGB0SE 0914TW Chapter 8-1

198 Ask your lubricant supplier for the safety data sheets according to DIN for the products they supply you with. These cover: Chemical and physical properties. Protective measures, storage and handling. Measures to be taken in the event of accidents and fi res. 8.3 Disposal of electrical and electronic components When disposing of electrical and electronic components, the local laws and regulations are to be observed. 8.4 Hydraulic oil and lubricant table ATTENTION On principle, a test run of the machine in the factory is carried out with zinc-containing oil. However, the machine can also be operated with a comparable zinc-free oil When delivered, the remaining amount is approx. 5 %, therefore, also the oil supplier has no objections about mixing the oil in this ratio. These products have been recommended to us by the mineral oil companies. Products from other companies which can be shown to be of the same quality may also be used. Chapter 8-2 VMRGB0SE 0914TW

199 Only use prefi ltered hydraulic oil of cleanliness class 17/15/12 acc. to ISO 4406! Lubrication point Hydraulic equipment*) Hydraulic equipment***) Gearbox, axial bearing and oil lubrication Central oil lubrication Central lubrication grease and grease Three-phase motor & electric motors**) Pneumatics & electromagnetic coupling Linear guide Designation to DIN HLP 46 DIN T2 HLP 32 DIN T2 CLP 220 DIN T3 CG 220 DIN T3 K 2/3 R - 40 DIN HLO 10 / CL 10 DIN T1 KP2 N-20 DIN Agip OSO 46 Agip OSO 32 Agip Blasia 220 Agip ASP 220 Agip Exidia Agip ACER 10 Aral Vitam GF 46 Aral Vitam GF 32 Aral Degol BG 220 Aral Deganit B220 - Aral Vitam DE 10 AVIA FLUID RSL 46 AVIA FLUID RSL 32 AVIA GEAR RSX 220 Slideway oil RSU AVIA FLUID RL 10-C BP Energol HLP-HM 46 BP Energol HLP-HM 32 BP Energol GR-XP 220 BP Maccurat 220 D - BP Energol HLP-HM 10 Castrol Hyspin AWS 46 Castrol Hyspin AWS 32 Castrol Alpha SP 220 Magnaglide D 220 SLX Grease Castrol Hyspin AWS 10 SPERROL EPL2 NUTO H 46 NUTO H 32 SPARTAN EP219 FEBIS K SPINESSO 9 HYDRAN TS 46 HYDRAN TS 32 GIRAN 220 HYDRAN G220 Pluton EM CIRKAN 10 Mobil DTE 25 Mobil DTE 24 Mobilgear 630 Mobil Vactra Oil No. 4 - Mobil Velocite Oil No. 6 RENOLIN B 15 VG 46 RENOLIN B 15 VG 32 RENOLIN CLP 220/220 Plus RENEP CGLP RENOLIN B 3 VG 10 Q8 Haydn 46 Q8 Haydn 32 Q8 Goya 220 Q8 Wagner Q8 Haydn 10 Shell Tellus S2 M 46 Shell Tellus S2 M 32 Shell Omala S2 G 220 Shell Tonna S3 M 220 Aero Shell Grease 16 Shell Morlina S2 BL 10 Alvania WR2 Klüber Synth GE TNK Hydraulic HLP 46 TNK Hydraulic HLP 32 TNK Reductor CLP Lukoil Geyser ST 46 Lukoil Geyser ST 32 Lukoil Steelo Gazpromneft Hydraulic HLP 46 Gazpromneft Hydraulic HLP 32 Gazpromneft Reductor CLP *) Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO 4406; always prefilter! **) Only for air cooled three-phase motors ***) In the case of ServoPower (option). Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO 4406; always prefi lter! VMRGB0SE 0914TW Chapter 8-3

200 8.5 Maintenance chart Every 160 operating hours All safety devices or all safety guards installed (including the mechanical scotch) Oil level in hydraulic tank Overall condition of machine (visual check). Always keep the switch cabinet doors closed. Make sure the switch cabinet is clean Check the fi lter mat(s) of the fans in the switch cabinet and the machine frame for clogging. Check hydraulic fi ttings, hose assemblies, cylinders, valves, pump(s) etc. for leakages and/or damages. Check air conditioning units (condensation water tank, fi lter), if present. Check the fi lling level of the central lubrication pump. Check lubricant fi lling amount of the central lubrication and refi ll if necessary! Every 500 operating hours Spray all bare parts (tiebars, piston rods, guide rails, linear guide of injection unit), where there is no movement with a corrosion inhibitorwith automatic lubrication, only visual checks and removing of impurities are necessary. Clean fi lters in electrical cabinet. Every 1000 operating hours Apply Molykotte grease GN-Plus to the gear rim for the rotary table drive (screw off the guarding, remove possible impurities). Lubricate the index cylinder (move the index cylinder forward and back several times). Check friction conditions of rotary table slideways at operating temperature. Normally, the used slideways should not be lubricated since the used sliding elements are designed self-lubricating, and starting problems may arise after standstill times due to the hardening of the lubricant. After the fi rst lubrication due to the following causes, lubrication should, however, be carried out periodically after every 1000 operating hours. Rotation time remains constant or slight deviation compared to the set rotation time (Rotation time difference < 20 % - no lubrication recommended Rotation time extremely increased (rotation difference > 20 %) - lubricate the rotary table platens on the corresponding lubrication points -Klübersynth GE ! lubricant Chapter 8-4 VMRGB0SE 0914TW

201 Diameter of circular table 752 mm mm: Bottom side of support platen Diameter of circular table 1280 mm mm: Central lubricant distributor at the right side of the machine frame. When a cooling agent comes in, an additional corrosion protection can be caused by the beginning of the lubrication cycle. If the rotary table is driven by a servo-motor, the drive as well as the slideways of the rotary table are supplied via an automatic lubrication - only visual checks necessary Every 2500 operating hours Operating manual available and correct. Check the heater bands for correct position and secure fi tting. Tighten all terminals in the switch cabinet. Check cables (for damage, scorching). Clean the fi lter mat(s) of the switch cabinet, fan. Heater bands checked for function and cleanliness. Check emergency-stop circuit. Replace hydraulic tank venting fi lter. Every 5000 operating hours Replace the diaphragm of the cooling water valve. Check nozzle for wear and concentricity Visual check of electrical components. Check nozzle for wear and concentricity Test hydraulic oil (replace if necessary) To establish the oil change interval suitable for the local operating conditions it is recommended to test the oil at fi rst after shorter intervals (e.g. monthly). An oil change must be carried out if the servo-motor option is installed and also for the "Axial bearing" of injection unit Check all fi ttings for security and tighten as necessary. Every operating hours Change hydraulic hose assemblies Rinse the oil cooler and cooling water fl ow governor with a descaling solution. Lubricate electric motor bearings VMRGB0SE 0914TW Chapter 8-5

202 8.6 Hydraulic system Work on hydraulic system may only be carried out by a skilled hydraulic technician! If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury! Switch off the main switch and use a padlock to prevent accidental reconnection. If the clamping platen, nozzle and screw are not in one of their end positions then the hydraulic system is relieved from pressure. Any residual pressure can be released by carefully loosening (but not completely undoing) a hydraulic screw connection Oil change Burning hazard if touched! At oil temperatures above 60 C (60,00 C) wear appropriate PPE! When disposing of used oil, legal requirements must be met. The proprietor of the machine is responsible for proper disposal! Every 5000 operating hours an oil sample should be taken and, depending on the analysis, an oil change be carried out. This assumes a maximum operating temperature of 60 C (140 F) and regular oil fi lter changes. To establish the oil change interval suitable for the local operating conditions it is recommended to test the oil at fi rst after shorter intervals (e.g. monthly). The test sample must be taken from the pressure line at operating temperature. Regardless of the usage the hydraulic oil should be changed after one year at the latest. If the oil is not changed or is changed too late the machine will be unreliable and damaged, especially as a result of abrasive contaminants in the hydraulic oil which can not be removed by the fi lter. Chapter 8-6 VMRGB0SE 0914TW

203 ATTENTION Leaked oil is always contaminated and must never be put back into the hydraulic tank! Ensure greatest cleanliness! The fi lling spout on the hydraulic tank, as well as the fi lling screws and screw plugs on the transport and storage tank of the hydraulic oil and the surroundings must be thoroughly cleaned beforehand; the oil should also be checked for possible ingress of water. If hydraulic oil becomes contaminated with water it will be of inferior quality and must not be used any further. The oil change should be carried out immediately after the end of a production run on the machine. This ensures that the oil is at operating temperature and viscosity (45 C to 50 C / 113 F to 122 F) and particles are still in suspension so that they can be pumped out with the oil. 1 Clean the fi ller screws and the screw plugs on transport and storage containers. 2 Check the hydraulic oil grade; see "Oil quality" 3 Prefi lter the hydraulic oil through a mobile fi ltration unit. 4 Switch off hydraulics ("Hydraulics stop" key). 5 Switch off main isolator and secure against accidental reconnection. 6 Clean the area round the venting fi lter. 7 Unscrew the venting fi lter lock and remove the complete venting fi lter from the pipe socket. 8 Empty hydraulic tank with a pump unit via the pipe socket. The hose must reach to the bottom of the tank. 9 Remove the tank cover; clean the hydraulic tank ATTENTION If the tank is filled above the maximum level, hydraulic oil will come out of the venting filter! The new hydraulic oil may only be fi lled through the air venting fi lters. This must be done through a separate fi ltration unit (fi lter mesh size 3 μm / μinch), which guarantees a cleanliness class of 15/12 acc. to ISO 4406 (Class 6 acc. to NAS 1638 or CETOP RP 70H) Experience has shown that even new oil is not this clean. ATTENTION Only use new hydraulic oil and under no circumstances mix different grades or different makes with each other. The type of oil should not be changed without compelling reasons. If this is the case, the system must be flushed out with the new oil first! VMRGB0SE 0914TW Chapter 8-7

204 To avoid mixing oils it is recommended to mark the oil tank and fi llers with the oil type. 1 Fill the hydraulic tank to the maximum mark with a mobile fi ltration unit The max. fi lling level is shown by the upper marking on the oil level indicator. 2 Place the venting fi lter on the pipe socket again. 3 Reconnect the bypass fi lter unit, if fi tted ATTENTION Before switching on the machine, the hydraulic oil should be allowed to stand for approx. 1 hour to let the air trapped during filling escape! Deaeration After fi lling the hydraulic tank air must be bled from the hydraulic system. Press the "Hydraulic start" key to switch on the hydraulics Press the "Setting" key. Drive the clamping platen, injection unit and injection cylinder several times to and fro over their whole stroke. Bleeding is carried out effectively when no foam appears in the hydraulic tank, movements are smooth and there are no strange noises. The oil level should be checked after bleeding and topped up if necessary. Care must be taken to use the same oil type Checking the oil level Continuous (daily) monitoring of the oil level is required as a drop in the oil level below the marked minimum volume may lead to an increase in operating temperature, undissolved air and pump failure from cavitation. Chapter 8-8 VMRGB0SE 0914TW

205 8.6.4 Oil change Axial bearing ATTENTION The oil level should be checked daily. The axial bearing should be checked daily for leaks and damage to the shaft seals Hydraulic filter Pressure fi lters are installed in front of components which require extra protection. The pressure fi lter has a contamination indicator which sends an error message to the screen if it is triggered. At the fi rst possible pause in production (e.g. shift change) the fi lter element must be replaced. If there are no spare fi lters available one must be ordered immediately. The article number can be found in the chapter "Spare parts / Plans". In principle the fi lter element should be changed at the same time as the oil. If the above error message or the oil analysis indicates an early oil change, then the oil fi lter should be changed early too. The greatest cleanliness must be maintained. The contamination indicator is suppressed at low temperatures; i.e. if the oil temperature is below 27 C (80.6 F) the switch does not function. VMRGB0SE 0914TW Chapter 8-9

206 8.6.6 Changing the filter element Switch off the machine and wait for complete pressure loss. If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury! Burning hazard if touched! At oil temperatures above 60 C (60,00 C) wear appropriate PPE! Unscrew fi lter housing (1). Run hydraulic oil into a suitable container Remove fi lter element (2); inspect the mesh surfaces for contamination and large particles. These can be an indication of damaged hydraulic components. Dispose of fi lter element (2) Before fi tting the fi lter element, check that the type designation is the same as that of the fi lter element removed. ATTENTION Never clean or reuse a filter element! Replace the fi lter element. The fi lter element can not be cleaned. Any attempt to clean the fi lter element can damage the fi lter material which will then allow contaminated oil to reach the clean side of the fi lter element. Clean the fi lter housing (1) (inside) with a suitable agent (e.g. white spirit, paraffi n/ kerosene) and make sure no dirt gets into the clean side. Chapter 8-10 VMRGB0SE 0914TW

207 Inspect the fi lter unit for mechanical damage, especially to sealing faces and seals. Renew damaged parts. Check O-rings (3 + 4) and change if damaged. ATTENTION If damaged components are not replaced and if the filter is not kept in perfect condition, other hydraulic components may be damaged or fail! Lightly oil the threads and sealing faces of the fi lter and the O-ring (3) of the fi lter element (2) with clean liquid Mount the fi lter element on its location. Screw the fi lter housing (1) right in. Start the hydraulic system under pressure and check the fi lter for leaks. If a leak is found then the corresponding O-ring should be renewed. VMRGB0SE 0914TW Chapter 8-11

208 8.6.7 Venting filter Venting fi lters allow fi ltered air to pass in and out of the oil tank as the oil level changes. Its effectiveness depends upon the environment, but it should be checked and if necessary the element renewed after 2500 operating hours at the latest, paying the greatest attention to cleanliness HM_1034.BMP Change the venting fi lter hydraulic tank Switch off the machine and wait for complete pressure loss. Remove guarding if necessary. Remove hexagon nut (1) (DIN 934 M10 SW 17) and washer. Lift off cover (2). Remove element (3) and mount new element. Put cover back on. Put on washer and screw on hexagon nut. Chapter 8-12 VMRGB0SE 0914TW

209 8.6.8 Leaks Observe any leaks in the hydraulic system and remedy them by resealing or tightening the screw connections. Damaged hydraulic hoses and hose assemblies must be renewed at once, please refer to the chapter "Hose assemblies". Regular checks of the hydraulic fi ttings, hose asemblies, cylinders, valves, pump(s) etc. must be carried out every 160 running hours Oil cooler Although the oil cooler may be considered maintenance free, it is recommended to give it some preventive maintenance every operating hours. Contaminated water must be fi ltered and if scale is present the cooling lines must be descaled. See also "Water quality". VMRGB0SE 0914TW Chapter 8-13

210 8.7 Pressure vessel 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! Before starting up the machine the nitrogen pressure within the pressure vessel (option) must be checked. In case the nitrogen pressure falls short of the indicated value (see name plate or hydraulic plan), nitrogen has to be refi lled. Pressure vessels are subject to the safety regulations applicable at the place of use. Before starting up the machine, they have to be accepted by the technical standards organisation (e.g. TÜV) responsible in the proprietor s region. The proprietor of pressure vessels is responsible for ensuring the proper condition, operation and monitoring. Neither welding nor soldering nor any mechanical processing may be performed on the pressure vessels. Improper repairs can cause severe accidents and may only be carried out by authorised customer service personnel Checking the nitrogen pressure Check the nitrogen pressure before and during operation as follows: 1 At least once within the fi rst 40 operating hours. Major losses in nitrogen will immediately be detected and be compensated. 2 In case no losses have been detected during the fi rst 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. ATTENTION The nitrogen pressure changes temperature dependently. For this reason, inspections should always be carried out under equal temperature conditions. After filling or discharging nitrogen please wait 5 minutes approx. until the temperature has been balanced. Check the nitrogen pressure afterwards! During each check nitrogen will escape through the filling unit. This will reduce the nitrogen pressure, especially in case of small pressure vessels! The pressure within the mobile nitrogen cylinder (for filling the pressure vessel) may not exceed the maximum permissible operating pressure of the machine s pressure vessel or the pressure gauge. Otherwise a pressure reducer has to be inserted between the mobile pressure cylinder and the filler! Please keep all certificates in a safe place! When demanding certfi cates later on, please state the contents, the factory number and the year of manufacture of the vessel. These data is embossed on both ends of the vessel. Chapter 8-14 VMRGB0SE 0914TW

211 8.7.2 Replenishing, reducing and testing the nitrogen pressure The fi lling and testing unit is not included in the standard delivery Connection for the nitrogen cylinder (Right-hand thread W24.32x 1 1/4") 2 - Non-return valve (valve insert) 3 - Button 4 - Pressure pin 5 - Valve gate 6 - Venting valve 7 - Union nut 8 - Seal element 9 - Connection piece (SAE 7/8" - 14UNF -2B) 10 - Gas fi lling valve 11 - Bubble accumulator 1 Mount the pressure gauge as described in "Checking the hydraulic pressure". 2 Switch off the machine at the main switch. 3 Wait for the pressure of the hydraulic oil within the pressure vessel to be reduced (until the pressure gauge indicates 0 bar / psi) 4 Unscrew the covering cap(s) of the gas fi lling valve. 5 Screw the fi ller unit to the gas fi lling valve. 6 Check whether the venting valve of the fi ller unit is closed. 7 Screw the hose assembly s connecting piece to the nitrogen bottle. 8 Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly fl owing into the pressure vessel (for the fi lling pressure please refer to the hydraulic plan or the respective label). 9 Close the shut-off valve after reaching the desired nitrogen pressure. 10 Use the venting valve to close the fi lling hose. 11 Press the button of the fi ller unit, release it and read off the nitrogen pressure at the pressure gauge. 12 In case the nitrogen pressure is too high, carefully press the pressure pin after opening the venting valve to reduce the pressure. Steps 7, 8 and 9 will be omitted when reducing or checking the pressure. VMRGB0SE 0914TW Chapter 8-15

212 8.7.3 Checking the hydraulic pressure 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! Screw a pressure gauge connection-hose assembly, which is not included in the standard delivery, to the fi tting of a pressure gauge. Clean the surroundings of the miniature measuring connection at the hydraulic block of the pressure vessel. Remove the sealing cap of the miniature measuring connection. Screw in the fi tting of the pressure gauge connection-hose assembly. You can only retrieve the hydraulic pressure within the pressure vessel from the pressure gauge. 8.8 Hose assemblies The safety regulations are laid down in DIN Parts 4 and 5 as well as in EN 201. They contain regulations on the testing, replacement and storage of hydraulic hose assemblies. The proprietor of the machine has a duty to ensure that hose assemblies are replaced at the appropriate intervals, even if no technical shortcoming is apparent in the hose assembly Service life Even with proper storage and in approved applications, hosing and hose assemblies undergo a natural ageing process which limits their service life. Improper storage, physical damage and non-approved application are the most common causes of failure. The service life (including storage time) for hoses and hose assemblies must not be exceeded. The date of manufacture is permanently marked on every hose and hose assembly. The hose assemblies have to be replaced after operating hours at the latest Chapter 8-16 VMRGB0SE 0914TW

213 Hoses which have already been in service as part of a hose assembly may not be reused as they no longer conform to the requirements of DIN If a hose is reused, then the liability lies with the person who fi ts the hose assembly. Only hose assemblies with swaged-on stand-pipe ends can be reused. The length of a hose assembly is defi ned as shown in the following diagram. Length including standpipe ends Inspection criteria The serviceability must be verifi ed by a hydraulics expert every 1000 operating hours. Hose assemblies must be replaced at once if any of the following criteria are established on inspection: Damage to the outer sheath which reaches the reinforcement (e.g. chafi ng, cuts or cracks). Embrittlement of the outer sheath (cracking of hose material). Deformation not consistent with the natural form of the hose assembly, in either the pressurised or the relaxed condition, or in fl exure, e.g. delamination or blistering (see also DIN Part 4) Permeability or porosity. Damage or deformation of the hose fi tting (affecting sealing); trivial surface damage is not a reason for replacement. Movement of the hose from the ferrule. Corrosion of the fi tting affecting function or strength. Assembly guidelines not followed (DIN Part 4). Storage or service periods elapsed. VMRGB0SE 0914TW Chapter 8-17

214 8.9 Hydraulic accessories If the machine s hydraulic system is equipped at the customer s wish with additional components, like bypass fi ltration units, then the corresponding operating instructions in the "Accessories" section of this technical documentation must fi rst be read, in its entirety, without fail. If the hydraulic system of the machine is not relieved of pressure before fitting or removing hydraulic component it may empty explosively with the risk of damage and injury! Before operating the machine, its safety regulations and the operating instructions of the hydraulic accessory in question must be observed without fail! The mounting and dismounting, setting, commissioning and repair of hydraulic accessories may only be carried out by authorised personnel! 8.10 Lubrication Manual grease lubrication Before greasing, the machine must be secured against accidental reconnection! The lubricating nipples should be treated every 500 operating hours with an ordinary grease gun (may be pneumatic) for DIN type lubricating nipples. The grade of grease can be seen in the "Hydraulic oil and lubricant table" Three phase motor The three-phase motor bearings have to be cleaned and regreased every running hours. The grade of grease can be seen in the "Hydraulic oil and lubricant table". Chapter 8-18 VMRGB0SE 0914TW

215 Screw drive Before checking, the machine must be secured against accidental reconnection! The axial bearing is arranged so that the leakage line from the hydraulic motor lubricates it. No maintenance is thus necessary in this case. The oil level must be checked before the fi rst start-up and, if necessary, oil must be fi lled in or refi lled in the "Axial bearing" of injection unit 8800 and if the servo-motor option is installed, refer to paragraph Corrosion protection All bare parts (tiebars, piston rods, guide rails), where no movement takes place should be sprayed every 500 operating hours with a corrosion inhibiting oil. VMRGB0SE 0914TW Chapter 8-19

216 8.11 Water system ATTENTION When using water piping note the corrosion stability of metallic materials against water in accordance with DIN 50930! Water piping and the respective fi ttings are to be weekly checked for corrosion and leakages by a skilled technician. 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 (122 F) wear appropriate PPE! Water quality If there are deviations from the following guidelines, please contact our technical customer service or one of our subsidiaries. The addresses can be found in the "Customer service" chapter. ph value: Water hardness: < 1.8 mmol / l (681 ppm / gal) Solids: < 0.03 (30 ppm) Filter mesh: < 100 μm (0.004 inch) In the relation of solids content to water hardness, it should be noted that the harder the cooling water is the lower the solids content has to be. If the level of suspended matter is over 0,03 (30 ppm), a water fi lter with a mesh size < 100 μm (0.004 inch) must be fi tted before the water system Closed cooling circuit system It is recommended to add a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel). We recommend ethylene glycol type 420 as an antifreeze (60 % water and 40 % ethylene glycol). This is suitable for a temperature range down to -30 C ( C) and is also a corrosion inhibitor. Chapter 8-20 VMRGB0SE 0914TW

217 Hydraulic oil temperature Check the hydraulic oil temperature in the oil tank daily. The machine is most effi cient at an oil temperature between 45 C and 50 C (113 F and 122 F). The current hydraulic oil temperature will be displayed on the screen (B2 = in the actual value fi eld "T12" on page 2 of the "Temperature control zones" screen page / B4 = "Barrel temperatures 1" screen page) Oil cooler Every running hours, the cooling tubes should be fl ushed out with a descaling solution to remove any limescale deposits (max. 16 bar / 232 psi) Cooling water flow governor Check cooling water fl ow governor daily for fl ow and leaks. Likewise check the cooling water connections and hoses for fl ow (no kinked hoses) and leaks. The sight glasses may need cleaning if the coolant is dirty. The consumers, moulds, throat cooling, etc. should be fl ushed out every operating hours with a descaling solution. VMRGB0SE 0914TW Chapter 8-21

218 8.12 Electrical equipment For all work involving fitting, removal, modification and maintenance, the legal rules and regulations and the safety instructions in the "Safety" chapter must be observed without fail! Work on electrical components may only be carried out by a qualified electrician! Filter mats The fi lter mats can be cleaned as follows: Washing in water (up to approx. 40 C / 104 F, with mild detergent if desired). Shaking, vacuuming or blowing out with air is also possible. If the dust is greasy the fi lter mat must be washed out in water with a grease dispersant additive Buffer battery The control unit is protected from data loss by a buffer battery. When the error message "Buffer battery fl at" appears, the battery has to be replaced. The battery must be replaced for the fi rst time after 5 years at the latest, then every 3 years. Battery change (type: lithium battery 3 V / 950 ma): ATTENTION Data loss without buffering! For security purposes, a copy of the service and tool record has to be filed on floppy disk before changing the battery. 1 Switch off the main switch. After changing the battery, the main switch has to be switched on again within 30 sec. so that no data are lost 2 Carry out an electrostatic discharge at the top hat rail or at the earth connection (do not reach into the power supply) 3 Open the battery compartment by means of a screw driver. Position the screw driver in the slot and open the compartment by lifting 4 Pull the battery out of the support by pulling at the battery compartment cover Chapter 8-22 VMRGB0SE 0914TW

219 5 Take out the lithium battery (do not touch the battery with pliers or uninsulated tweezers -> short circuit). Only touch the battery on the front side with your hands. Insulated tweezers can also be used to take out the battery. 6 Position the new battery with the correct polarity. The removal strip must be located underneath the battery, otherwise the battery cannot be extracted 7 Close the cover of the lithium battery 8 Switch on the main switch When disposing of batteries, the legal requirements must be met. The proprietor of the machine is responsible for proper disposal! VMRGB0SE 0914TW Chapter 8-23

220 8.13 Pneumatic system If the pneumatic system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! UNIFEED material feeder The secondary fi lter (3) of UNIFEED material feeder (option) should be cleaned as necessary and in any case inspected at least once a week, depending on the amount of dust. Its service life is limited and it should be renewed at the fi rst sign of loose fi bres (by simply removing it from its holder). The primary fi lter (2) is automatically cleaned by compressed air after every conveying cycle. If it becomes clogged it is cleaned as follows: 1 Turn off air supply. 2 Remove knurled nuts (4). 3 Lift off cover (1). 4 Clean and insert primary fi lter (2) again. 5 Insert cover. 6 Do up knurled nuts (4). When fi tting the fi lter care must be taken to position the fi lter O-ring properly in the groove provided. Chapter 8-24 VMRGB0SE 0914TW