husky hypet 400

HyPET Injection Molding MachineOperator Manual

Original Instructions

HyPET Injection Molding Machine

ii v 2.6 April 2012

Issue: v 2.6 April 2012

This product manual is intended to provide information for safe operation and/or maintenance. Husky reserves the right to make changes to products in an effort to continually improve the product features and/or performance. These changes may result in different and/or additional safety measures that are communicated to customers through bulletins as changes occur.

This document contains information which is the exclusive property of Husky Injection Molding Systems Limited. Except for any rights expressly granted by contract, no further publication or commercial use may be made of this document, in whole or in part, without the prior written permission of Husky Injection Molding Systems Limited.

Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission to its customers to reproduce this document for limited internal use only.

Husky product or service names or logos referenced in these materials are trademarks of Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies under license.

All third-party trademarks are the property of the respective third-party and may be protected by applicable copyright, trademark or other intellectual property laws and treaties. Each such third-party expressly reserves all rights into such intellectual property.

2008-2012 Husky Injection Molding Systems. All rights reserved.

General Information iii

Operator Manual v 2.6 April 2012

General Information

Equipment Identification

Telephone Support Numbers

For on-site service, contact your nearest Husky Regional Service and Sales office.

For non-emergency questions and issues you may also e-mail Husky at [email protected].

Figure 1 Nameplate Location (Typical)

1. Machine Nameplate 2. Model Number 3. Serial Number 4. Warranty Start Date 5. Certification Symbols

MACHINE MODEL

SERIAL NUMBER

MO/YR OF MFG.

ELECTRICAL DIAGRAM

HPN 3213627

SUPPLY No.1 LOAD

LARGEST MOTOR

TOTAL HEAT LOAD

SUPPLY No.2 LOAD

LARGEST MOTOR

TOTAL HEAT LOAD

SUPPLY No.3 LOAD

LARGEST MOTOR

TOTAL HEAT LOAD

HUSKY INJECTION MOLDING SYSTEMS LTD.

V

A

A

V

A

A

V

A

A

A

A

A

SHORT-CIRCUIT

INTERRUPTING CAPACITY

SHORT-CIRCUIT


SHORT-CIRCUIT


Hz

Hz

Hz

BOLTON, ONTARIO, CANADA L7E 555

CERTIFICATION

System

kA

System

kA

System

kA

R

1

2

3

4

5

North America Toll free 1-800-465-HUSKY (4875)

Europe EC (most countries) 008000 800 4300

Direct and Non-EC + (352) 52115-4300

Asia Toll Free 800-820-1667 or +800-4875-9477

Direct: +86-21-3849-4520

Latin America Brazil +55-11-4589-7200

Mexico +52-5550891160 option 5

v 2.6 April 2012 HyPET Injection Molding Machine

iv Ordering Additional Manuals

Ordering Additional Manuals

Additional copies of this manual and other documentation can be purchased through your nearest Husky Regional Service and Sales office.

vOperator Manual v 2.6 April 2012 Table of Contents

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiEquipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiiTelephone Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiiOrdering Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 Purpose of the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.5.1 Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5.2 Drawings and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.5.3 Safety Alert Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.7 Machine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Chapter 2: Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.1 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3 Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3.1 Mechanical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3.2 High Pressure Leak Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.3 Burn Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.4 High Pressure Explosion Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.5 Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.6 Noise Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3.7 Gas, Vapor and Dust Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3.8 Slip, Trip or Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3.9 Lifting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.4 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.5 Guards and Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.6 Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.6.1 Performing Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.6.2 Removing Locks and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.7 Personal Protective Equipment and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 182.7.1 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18


vi

2.7.2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.8 Material Safety Data Sheet (MSDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.9 Materials, Parts and Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.10 Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.10.1 Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.10.2 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212.10.3 Product Handling Gate Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.10.4 Safety Gates and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.10.5 Mechanical Safety Device (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232.10.6 CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232.10.7 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.10.8 Manual Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.10.9 Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.10.10 Electrical Cabinet Door Interlocks and Override (UL only) . . . . . . . . . . . . . . . . . . 25

Chapter 3: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Chapter 4: Human Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294.1 Access Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.2 Default User Name and Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.3 Logging On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.3.1 Logging On With a Datakey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314.3.2 Logging On With a Username and Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4 Logging Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324.5 General Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.5.1 Sidebar Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344.5.1.1 Accessing the Function Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344.5.1.2 Standard Sidebar Function Groups and Sidebar Icons . . . . . . . . . . . . . . . . . 354.5.1.3 Function Group, Function and Process Value Icons Explained . . . . . . . . . 37

4.5.2 Cycle Mode Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374.5.3 Robot Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384.5.4 Pump Motor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384.5.5 Main Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394.5.6 Screen Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414.5.7 Manual Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414.5.8 Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434.5.9 Common Screen Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5.9.1 Alphanumeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434.5.9.2 Numeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444.5.9.3 Common Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.6 Setting the Machine Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464.7 Generating On-Demand and Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.7.1 Report Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Operator Manual v 2.6 April 2012 Table of Contents

4.7.2 Generating On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.7.3 Enabling Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.7.4 Viewing Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.7.5 Printing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.7.5.1 Printing On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514.7.5.2 Printing Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.7.6 Saving Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.7.6.1 Saving On-Demand Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.7.6.2 Saving Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.8 Graphing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.8.1 Common Graphing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554.8.2 Generating a Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.9 Assigning Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.10 Enabling/Disabling the Booster Cylinders (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . 57

Chapter 5: Starting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595.1 Inspecting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605.2 Powering Up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605.3 Logging On to the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.4 Checking the Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.5 Checking the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.6 Checking and Resetting the Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.7 Warming the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645.8 Checking the Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665.9 Checking the Product Handling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665.10 Checking/Enabling the Mold Related Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675.11 Cycling the Machine and Product Handling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675.12 Turning On the Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.12.1 Turning on the Machine, Mold and Nozzle Tip Heats (RS80/80). . . . . . . . . . . . . 685.12.1.1 Turning on the Machine Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685.12.1.2 Turning on the Mold Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695.12.1.3 Turning on the Nozzle Tip Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.12.2 Turning on the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.12.3 Enabling Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.12.4 Configuring the Temperature Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.12.4.1 Configuring an Individual Temperature Setpoint for a Machine or Mold Heat Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.12.4.2 Configuring Individual Temperature Setpoints for Nozzle Tip Heat Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.12.4.3 Configuring a Global Temperature Setpoint for Machine or Mold Heat Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.12.4.4 Configuring a Global Temperature Setpoint for Nozzle Tip Heat Zones 82


viii

5.13 Preparing the Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835.13.1 Opening the Process Material Feed Manual Shutoff (If Equipped) . . . . . . . . . . 845.13.2 Opening the Process Material Feed Auto-Shutoff (If Equipped). . . . . . . . . . . . . 845.13.3 Opening the Magnet Drawer (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.14 Purging the Injection Unit Before Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865.15 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen. . . . . . . . . . . 865.16 Inspecting the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865.17 Precharging the Hot Runner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875.18 Producing Test Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 895.19 Setting Up SmartStart (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915.20 Setting Up SmartStop (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

5.20.1 Stopping on a Critical Machine Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945.20.2 Stopping After Producing Extra Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955.20.3 Stopping After Completing Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955.20.4 Stopping on a Specific Day and Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.21 Starting Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 975.21.1 Starting Production Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 975.21.2 Starting Production with SmartStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 6: Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .996.1 Stopping the Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996.2 Pausing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1006.3 Stopping the Machine in a Controlled Manner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

6.3.1 Stopping Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1046.3.2 Shutting Off the Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1046.3.3 Purging the Injection Unit After Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1066.3.4 Turning Off All the Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

6.3.4.1 Turning Off the Machine, Mold and Nozzle Tip Heats (RS80/80) . . . . . .1076.3.4.1.1 Turning Off the Machine Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1076.3.4.1.2 Turning Off the Mold Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1076.3.4.1.3 Turning Off the Nozzle Tip Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

6.3.4.2 Turning Off the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

6.3.5 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen . . . . .1106.3.6 Emptying the Hopper/Direct Feed Tube (Optional) . . . . . . . . . . . . . . . . . . . . . . .1106.3.7 Cleaning the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1136.3.8 Turning Off Mold Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1136.3.9 Turning Off the Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1136.3.10 Powering Down the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

6.4 Unexpected Machine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Chapter 7: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1177.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

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Operator Manual v 2.6 April 2012 Table of Contents

7.1.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1187.1.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1187.1.3 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

7.2 Draining the Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1227.3 Cleaning the Nozzle Tip, Stationary Platen and Purge Guard . . . . . . . . . . . . . . . . . . .1237.4 Checking the Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

7.4.1 Checking the Emergency Stop Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1247.4.2 Checking the Safety Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1257.4.3 Checking the Mechanical Safety Device (If Equipped) . . . . . . . . . . . . . . . . . . . . .1277.4.4 Checking the Automatic Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1287.4.5 Checking the Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1287.4.6 Checking the CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

7.5 Cleaning the Machine and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1307.6 Checking the Hydraulic Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1307.7 Purging the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

7.7.1 Manually Purging the Injection Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1317.7.2 Auto Purging the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

7.8 Changing the Resin Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136


x

Operator Manual v 2.6 April 2012 Introduction

Purpose of the Equipment 1

Chapter 1 Introduction

This chapter describes the machine, training opportunities, and the available equipment manuals.

1.1 Purpose of the Equipment

Husky equipment and systems are designed for injection molding applications only, using approved materials and operating within design guidelines.

Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky product for anything other than its intended use.

1.2 Restrictions of Use

Husky injection molding equipment must never be:

used for any purpose other than that described in Section 1.1, unless otherwise approved by Husky

used to extrude metal or food compounds operated or serviced by personnel unfamiliar with the inherent risks and necessary

precautions related to injection molding equipment operated at temperatures higher than the maximum presumable temperature for

plasticizing operated by more than one person

1.3 Unauthorized Modifications

Unauthorized modifications or reconstruction of any Husky injection molding system is strictly prohibited. Modifications, such as the substitution or removal of components, can be unsafe and/or void warranty.

Contact your nearest Husky Regional Service and Sales office to discuss modifications or requirements for Husky systems.


2 Auxiliary Equipment

1.4 Auxiliary Equipment

Husky is only responsible for the interaction of Husky equipment and systems with auxiliary equipment when Husky is the system integrator. If auxiliary equipment is removed, proper safeguards must be installed.

For information about integrating non-Husky auxiliary equipment, contact your nearest Husky Regional Service and Sales office.

1.5 Documentation

Each Husky machine is delivered with a Documentation CD that contains a full set of manuals, drawings, certificates and other documentation needed by operators and service technicians. Documentation is also available online through www.husky.ca.

Printed manuals and drawings from the Original Equipment Manufacturers (OEMs) are also provided with the machine when available.

1.5.1 Manuals

Husky manuals aid in the safe and proper use of Husky products. Where applicable, the manuals provide instructions on installation, operation and maintenance.

Personnel should thoroughly review all manuals provided with their Husky equipment prior to performing any tasks. Proceed with tasks only if all instructions are understood and always follow applicable workplace safety requirements.

The following manuals are provided with each Husky machine upon delivery:

IMPORTANT!If a Husky mold is equipped, refer to the separate Documentation CD provided with the mold for operation, installation and service information.

IMPORTANT!Keep all CDs and printed documentation in a convenient location for future reference.

Site Preparation Manual Describes preparing the site and receiving/handling the machine

Operator Manual Describes operator controls, startup and shutdown procedures, production controls, and daily maintenance requirements

Service Manual Includes specifications and requirements, installation procedures, scheduled maintenance procedures, corrective maintenance procedures and troubleshooting

Drawings and Schematics 3


1.5.2 Drawings and Schematics

Each Husky machine is provided with a set of drawings and schematics specific to the machine. These are used for troubleshooting the machine and ordering spare parts.

NOTE: Each drawing and schematic is specific to the machine it is provided with.

1.5.3 Safety Alert Conventions

Safety alerts highlight hazardous conditions that may arise during installation, operation or maintenance and describe methods for avoiding personal injury and/or property damage.

Depending on the severity of the hazard, safety alerts start with one of the following signal words: Danger, Warning or Caution.

Other non-safety related alert types used in the manuals highlight important information needed by the user to install, operate or maintain the machine properly. They may also, in some cases, describe best practices, offer an expanded explanation, or reference a related section in the manual.

Non-safety related alerts start with one of the following signal words: Note, Important, or Reminder.

NOTE: The NOTE alert is used to add information to a subject that does not fit within the general flow of the document.

IMPORTANT!Some manuals may contain addendums that detail new or updated information. Before reading a manual, make sure to review all available addendums located at the end of the manual.

DANGER!The DANGER safety alert indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING!The WARNING safety alert indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION!The CAUTION safety alert indicates a potentially hazardous situation that, if not avoided, could result in property damage.


4 Training

1.6 Training

All designated operators and maintenance personnel must be fully trained before using or servicing Husky injection molding systems.

If training is required, visit www.husky.ca or contact your nearest Husky Regional Service and Sales office to learn more about Huskys training solutions.

1.7 Machine Layout

Throughout this manual and other documentation provided with the machine, references will be made to specific areas of the machine. The illustration below describes these areas and the standard terminology used to reference them.

IMPORTANT!The IMPORTANT alert is used to highlight important steps, conditions, or considerations related to the subject.

IMPORTANT!It is the obligation of the employer to properly train and instruct all personnel in safe methods of operation and maintenance. Manuals and other reference material, which have been prepared by Husky for the operation and maintenance of Husky equipment, do not in any way absolve the employer from fulfilling these obligations and Husky disclaims liability for injury to personnel which is attributable to the employer's failure to do so.

Machine Layout 5


Figure 1-1 Machine Orientation (Typical)

1. Clamp End 2. Non-Operator Side 3. Injection End 4. Operator Side 5. Clamp Unit and Product Handling Area 6. Injection Unit 7. Operator Work Area

7

65


6 Machine Layout

Operator Manual v 2.6 April 2012 Safety Summary

Qualified Personnel 7

Chapter 2 Safety Summary

This chapter describes the general requirements and conditions for safe operation of the machine.

2.1 Qualified Personnel

Only fully trained and qualified personnel should be permitted to operate equipment. Qualified personnel must have demonstrated skills and knowledge related to injection molding equipment, as well as training to recognize potential hazards.

2.2 Safety Guidelines

Personnel operating, installing, maintaining or servicing Husky equipment must adhere to safe working practices that are in compliance with the following guidelines:

Use an appropriate ladder or platform to access areas of the machine. Lockout and tag electrical, pneumatic and hydraulic energy sources before servicing the

machine or entering the mold area. Depressurize the hydraulic system using the manual dump valve before servicing any

hydraulic component. Do not climb over Husky equipment while the machine is in operation. Do not operate the machine unless all guards are in place. Do not operate the machine if a safety interlock is bypassed, modified or damaged. Do not operate the machine if any component or system is missing or damaged.

IMPORTANT!Personnel must read, understand and follow all safety precautions.

IMPORTANT!Personnel must follow applicable industry and regulatory safety requirements for safe installation, operation and maintenance of equipment.


8 Safety Hazards

Do not operate the machine if scheduled preventive maintenance has not been performed.

Do not use a magnetic platen without approval from Husky and the magnetic platen supplier/manufacturer.

2.3 Safety Hazards

Some common safety hazards associated with injection molding equipment are:

Mechanical (pinching, shearing, crushing) High Pressure Leak Burn Explosion Electrical Noise Gas, Vapor and Dust Emissions Slip, Trip or Fall Lifting

2.3.1 Mechanical Hazards

Worn Hoses and Safety RestraintsRegularly inspect and replace all flexible hose assemblies and restraints.

Cooling Water HosesCooling water hoses degrade over time and need to be replaced on a yearly basis. Cooling water hoses routed in the vicinity of the barrel are exposed to high temperatures that shorten their useful life and can require more frequent replacement. Degraded hoses become brittle and can break or separate from the fitting when manipulated. To minimize the risk of failure, inspect the hoses regularly and replace as required.

Make sure to wait until the machine has cooled down before servicing cooling water hoses.

Injection and Clamp UnitsHydraulic circuits in injection and clamp units contain high pressure accumulators. Before servicing hydraulic systems, lock out and tag the machine to discharge all stored energy. When servicing hydraulic systems, read the equipment manuals and refer to hydraulic schematics for additional details.

High Pressure Leak Hazards 9


2.3.2 High Pressure Leak Hazards

Hydraulic SystemFlexible hose connections and piping in hydraulic systems must be properly tightened to prevent the release of fluids or gases under pressure. Hoses must be inspected periodically for signs of sweating and/or blistering. Steel tubes should be tested using dye penetrant.

Skin Puncture InjuriesHigh pressure hydraulic spray can penetrate human tissue and cause severe bodily injury. Seek immediate medical help in any event of skin puncture by fluid spray.

2.3.3 Burn Hazards

Hot SurfacesThe mold area, auxiliary mold equipment, and injection unit heating elements have numerous high temperature surfaces. At normal operating temperatures, contact with these surfaces will cause severe skin burns. These areas are clearly marked with safety signs. Wear personal protective equipment when working in these areas.

Molten MaterialNever touch process material purged or otherwise flowing from the nozzle, mold, hot runner or feed throat area. Molten material can appear cool on the surface, but remain very hot on the inside. Wear personal protective equipment when handling purged material.

2.3.4 High Pressure Explosion Hazards

Pressure can build up in a nozzle or feed throat area and cause some process material to explode. In some cases, molten material can be ejected unintentionally due to insufficient pre-drying or degradation of process materials. These areas are clearly marked with safety signs. Be aware of these areas. Wear appropriate personal protective equipment when accessing these areas.

2.3.5 Electrical Hazards

Molding equipment draws high power. The electrical requirements are indicated on the electrical nameplate on the electrical cabinet, and in the electrical schematics. Connect equipment to a suitable power supply as specified in the electrical schematics and in compliance with all applicable local regulations.

WARNING!High pressure spray hazard risk of death or serious injury. High pressure hydraulic oil spray can penetrate human tissue and cause extensive injuries. Lock out and tag the machine before servicing any hydraulic component.


10 Noise Hazards

2.3.6 Noise Hazards

When the machine is at idle, the average noise level in the operators work area is 85 dB(A), as measured according to DIN 45 635-T1-Class 2.

The peak noise level will vary depending on processing conditions.

2.3.7 Gas, Vapor and Dust Emissions

Certain processed materials release harmful gas, vapors or dust. Install an exhaust system according to local codes.

2.3.8 Slip, Trip or Fall Hazards

Do not walk, stand, climb or sit on machine surfaces.

Use an approved platform or walkway around equipment to reach areas that are not accessible from the floor.

2.3.9 Lifting Hazards

When lifting equipment, use suitable lifting devices, proper balancing techniques and designated lifting points. Refer to the installation details for handling and lifting instructions. Do not exceed the rated capacity of the lifting equipment.

2.4 Safety Signs

Safety signs clearly mark potentially hazardous areas in or around equipment. For the safety of personnel involved in equipment installation, operation and maintenance, use the following guidelines:

Verify that all signs are in the proper locations. Refer to the drawing package for details. Do not alter signs. Keep signs clean and visible. Order replacement signs when necessary. Refer to the drawing package for part

numbers.

WARNING!All personnel in the machine area must wear appropriate hearing protection if noise emission levels exceed 85 dB(A). Prolonged exposure to excessive noise levels can cause hearing loss.

Make sure noise levels are in compliance with all applicable local regulations.

Safety Signs 11


The following safety symbols may appear on safety signs:

NOTE: Safety signs may include a detailed explanation of the potential hazard and associated consequences.

Safety Symbol General Description of Symbol

GeneralThis symbol indicates a potential personal injury hazard. It is usually accompanied by another pictogram or text to describe the hazard.

Hazardous VoltageThis symbol indicates a potential electrical hazard that can cause death or serious injury.

Molten Material and/or High Pressure GasThis symbol indicates the presence of a molten material or high pressure gas hazard that can cause death or severe burns.

Lockout/TagoutThis symbol identifies an energy source (electrical, hydraulic or pneumatic) that must be de-energized before maintenance is performed.

Crushing and/or Impact PointsThis symbol indicates a crushing and/or impact area that may cause serious crushing injury.

High PressureThis symbol indicates a heated water or steam hazard that may cause severe burns.

High Pressure AccumulatorThis symbol indicates the sudden release of high pressure gas or oil can cause death or serious injury.

Hot SurfacesThis symbol identifies the presence of exposed hot surfaces that will cause serious burn injuries.

Slip, Trip or Fall HazardThis symbol indicates a slip, trip or fall hazard that can cause injury.


12 Guards and Interlocks

2.5 Guards and Interlocks

Guards are provided where hazards exist. There are two types of guards: movable and fixed.

Movable guards are interlocked to stop hazardous motion when the guards are moved or removed.

Fixed guards are not interlocked. Fixed guards must be installed and completely secured anytime power is applied to the machine.

Crushing HazardThis symbol indicates the presence of a crushing hazard at the rotating screw that can cause serious injury.

Read Manual Before OperationThis symbol indicates that qualified personnel should read and understand all instructions in the equipment manuals before working on the equipment.

Class 2 Laser BeamThis symbol indicates a laser beam hazard that can cause serious injury with prolonged exposure.

Barrel Cover Grounding StrapThis symbol indicates an electrical hazard related to the barrel cover grounding strap that can cause death or serious injury.

Safety Symbol General Description of Symbol

IMPORTANT!Before operating the equipment, make sure of the following:

Safeguards are in place Safeguards are not bypassed or modified Safeguards are tested and inspected regularly for correct operation Only qualified personnel perform maintenance tasks

Lockout/Tagout 13


2.6 Lockout/Tagout

Lockout/tagout must be performed on the complete system before performing any maintenance tasks or entering the mold area. Lockout/tagout includes de-energizing all systems, isolating all energy sources, and applying locks and tags to all energy sources.

2.6.1 Performing Lockout/Tagout

To lock out and tag the machine, do the following:

IMPORTANT!For detailed lockout/tagout instructions for auxiliary equipment refer to the original equipment manufacturer's documentation, along with all applicable local regulations and codes.

IMPORTANT!When troubleshooting electronics, lockout/tagout may not be possible. In this case, service personnel must secure the work cell by installing a Danger sign at all isolation points and cordoning off the area around the equipment.

WARNING!Hazardous risk of death or serious injury. Before starting the lockout/tagout procedure, read and understand the entire procedure. Failure to perform the lockout/tagout procedure correctly, before performing any service and/or maintenance activities, could result in death or serious injury.

DANGER!Electrocution hazard risk of death or serious injury. Install a danger sign at all isolation points and block off the area around the machine. When live troubleshooting is required, do not work alone. Have emergency medical assistance nearby throughout the procedure.

WARNING!Electrocution hazard risk of death or serious injury. Exposure to an electric arc flash could cause second degree burns. Wear arc rated personal protective equipment conforming to the National Fire Protection Association standards, or the equivalent local arc flash regulations.


14 Performing Lockout/Tagout

1. If equipped, move the Q3M breaker switch to the OFF position. This turns off power to motion control.

NOTE: For machines shipped to European countries with the integrated mold heats option, the Q1M breaker controls power to the machine, Human Machine Interface (HMI) and mold heats.

2. Move the Q2M breaker switch to the OFF position. This turns off power to the integrated mold heats.

3. Move the Q1M breaker switch to the OFF position. This turns off power to the machine and HMI.

4. Attach a lock and tag to each breaker switch and wait 10 minutes for residual voltage to discharge.

5. Using a calibrated voltmeter, make sure all power to the machine is switched off.

WARNING!Hazardous voltages, high pressure fluids, crushing or impact hazards risk of death or serious injury. Perform the lockout/tagout procedure in accordance with local codes.

Only qualified personnel should lock out and tag the machine.

Figure 2-1 Breaker Switches (Typical)

1. Toggle Switch (If Equipped) 2. Rotary Switch (If Equipped) 3. Q2M Breaker Switch 4. Q1M Breaker Switch 5. Q3M Breaker Switch (If Equipped)

CAUTION!Electrical hazard risk of component damage. When powering down the machine, switch off the Q3M (if equipped) and Q2M breaker switches before switching off the Q1M breaker switch. Failure to do so can result in unnecessary wear on components and lead to premature failure.

4

5

3

1

2

Performing Lockout/Tagout 15


6. On the power manifold, remove the gauge port cap and attach a hydraulic pressure gauge to each gauge port used to measure hydraulic pressure in the accumulators. The gauge must be rated for pressures higher than the machine operating pressure and have a quick disconnect fitting.

Refer to the hydraulic schematic for the specific location of the gauge port(s).

7. At the power manifold, turn each manual dump valve counter-clockwise to make sure the accumulator(s) discharge.

8. Check the hydraulic pressure gauge to verify the accumulator is completely discharged.

9. Turn the shutoff lever on the air regulator to turn off the compressed air supply.

10. Attach a lock and tag to the shutoff lever.

WARNING!Trapped hydraulic pressure - risk of serious injury. After depressurizing the hydraulic system, and locking and tagging any energy source, verify that all pressure has been discharged before servicing the machine.

Figure 2-2 Manual Dump Valve (Typical)

1. Power Manifold Assembly 2. Manual Dump Valve

1

2

WARNING!Trapped hydraulic pressure hazard risk of serious injury. Some hydraulic circuits, other than the accumulator circuit(s), may be designed to contain hydraulic pressure when the machine has been shut down. Make sure to relieve pressure from these circuits before performing any maintenance on related components.


16 Removing Locks and Tags

2.6.2 Removing Locks and Tags

To remove locks and tags from the machine, do the following:

1. Make sure a hydraulic pressure gauge or cap is in place for all gauge ports.

2. Make sure all power cables are properly connected.

3. Make sure all personnel are outside the safety barriers.

Figure 2-3 Air Regulator With Lock and Tag (Typical)

1. Air Regulator 2. Shutoff Lever 3. Lock 4. Tag

2

3

4

1

WARNING!Hazardous voltages, high pressure fluids, crushing or impact hazards risk of death or serious injury. Follow local codes when removing locks and tags. Only qualified personnel should lock out and tag the machine.

IMPORTANT!Locks and tags should only be removed by the person who installed them.

If the person is unable to personally remove the lock and tag, verbal instructions can be given to remove the lock and tag. The instructions must include any specific measures required to return the machine to safe operating condition.

If the person cannot be contacted, a supervisor and qualified technician (who has a thorough understanding of the machine) can remove the locks and tags. The locks and tags should only be removed when both the supervisor and technician agree that all systems are in order and there is no potential for injury.

Removing Locks and Tags 17


4. Move the Q1M breaker switch to the ON position. This turns on power to the machine and Human Machine Interface (HMI).

NOTE: For machines shipped to European countries with the integrated mold heats option, the Q1M breaker controls power to the machine, HMI and mold heats.

5. Move the Q2M breaker switch to the ON position. This turns on power to the integrated mold heats.

6. If equipped, move the Q3M breaker switch to the ON position. This turns on power to motion control.

7. At the power manifold, turn each manual dump valve clockwise completely to allow the accumulator(s) to charge when the machine is started.

8. Remove the lock and tag from the air regulator.

CAUTION!Electrical hazard risk of component damage. When powering up the machine, switch on the Q1M breaker switch before switching on the Q3M (if equipped) or Q2M breaker switches. Failure to do so can result in unnecessary wear on the components and lead to premature failure.

Figure 2-4 Breaker Switches (Typical)

1. Toggle Switch (If Equipped) 2. Rotary Switch (If Equipped) 3. Q2M Breaker Switch 4. Q1M Breaker Switch 5. Q3M Breaker Switch (If Equipped)

4

5

3

1

2


18 Personal Protective Equipment and Safety Equipment

9. Turn the shutoff lever on the air regulator to turn on the air supply for the machine.

2.7 Personal Protective Equipment and Safety Equipment

Personal injury can be avoided when personnel wear appropriate protective gear and use special safety equipment. The following describes the safety gear and equipment that should be used when working with the machine and any auxiliary equipment.

2.7.1 Personal Protective Equipment (PPE)

Wear appropriate personal protective equipment when working on or near equipment.

Standard personal protective equipment includes:

Safety glassesFor protecting the eyes from flying objects/particles, heat, sparks, splash from molten material, and more

Face shieldFor protecting the entire face area from flying objects/particles, heat, sparks, splash from molten material, and more

Heat resistant glovesFor protecting the hands from extreme heats

Hearing protectionFor protecting the ears from loud ambient noise

Safety shoesFor protecting the feet from electrical shocks, crushing hazards, puncture hazards, splash from molten material, and more

Non-Melting Natural Fiber Pants and Long-Sleeve Shirt

Figure 2-5 Air Regulator With Lock and Tag (Typical)

1. Air Regulator 2. Shutoff Lever 3. Lock 4. Tag

2

3

4

1

Safety Equipment 19


For protecting the body from potential splash from molten material

2.7.2 Safety Equipment

Use appropriate safety equipment when working on or near equipment.

Standard safety equipment includes:

Exhaust FanFor collecting potentially harmful plastic fumes

Purging ContainerFor containing hot resin purged from the injection unit

Vacuum CleanerFor collecting spilled resin pellets and other debris that may create a falling hazard

Stairs and LaddersFor ensuring safe access to areas of the machine

Danger SignsFor warning other personnel to stand clear of a component or area of the machine

Locks and TagsFor preventing the use of specific systems and components

Fire ExtinguishersFor the expedient suppression of small fires

Telescopic MirrorFor safely inspecting hot runner nozzle tips from outside the mold area

2.8 Material Safety Data Sheet (MSDS)

The Material Safety Data Sheet (MSDS) is a technical document which indicates the potential health effects of a hazardous product. It contains safety guidelines to protect personnel, as well as information about use, storage, handling, and emergency procedures.

Always refer to the applicable Material Safety Data Sheet before doing the following:

handling a chemical product disassembling any portion of Husky equipment that may result in exposure to a

chemical product

Contact the material supplier to obtain a copy of the MSDS sheet.

WARNING!Chemical hazard - Some of the chemicals used with Husky equipment are potentially hazardous and may cause injury and illness. Before storing, handling, or working with any chemical or hazardous material, thoroughly read and understand each applicable Material Safety Data Sheet (MSDS), use recommended personal protective equipment and follow the manufacturers instructions.


20 Materials, Parts and Processing

2.9 Materials, Parts and Processing

To prevent personal injury or damage to the equipment, make sure of the following:

The equipment is only used for its intended purpose, as described in the manuals The operating temperatures do not exceed the specified permissible maximum value The maximum temperature set point is set below the ignition point of the material

being processed Lubricants, oils, process materials and tools used on equipment meet Husky

specifications Only authentic Husky parts are used

2.10 Safety Devices

The machine is equipped with a number of safety devices designed to ensure the safety of the operator.

2.10.1 Warning Device

The warning device alerts the operator and other personnel to conditions occurring in the machine. A standard warning device is installed on the clamp unit and features three warning lights: red, amber and blue.

The red warning light activates when the machine stops due to an alarm condition. An optional audible horn also sounds to indicate the alarm condition.

The blue warning light combined with a different optional audible horn indicates a pending warning on the software alarm screen. This feature gives an early warning to the operator that a cycle interruption will occur if not addressed.

The amber warning light indicates an SPC-related alarm.

Emergency Stop Button 21


2.10.2 Emergency Stop Button

Emergency stop (or E-stop) buttons are used to stop the machine in the event of an emergency. When pressed, all motors will stop, all heats will turn off, all solenoids will de-energize, and all hydraulic oil will return to the hydraulic tank.

This machine is equipped with two emergency stop buttons. The buttons are located:

On the operator side below the Human Machine Interface (HMI) On the non-operator side inside the product handling area

To use an emergency stop button:

1. Push the emergency stop button to stop all machine motions and de-energize all systems.

2. Correct the condition that prompted the use of the emergency stop button.

3. Pull the button to reset it.

Figure 2-6 Warning Device (Typical)

1. Red Light 2. Amber Light 3. Blue Light 4. Horn

21

3

4

Figure 2-7 Emergency Stop Buttons

1. Operator Side 2. Non-Operator Side

2

1


22 Product Handling Gate Reset

2.10.3 Product Handling Gate Reset

Opening any product handling gate on the non-operator side of the machine will trigger an alarm and prevent the machine from operating.

Press the Gate Reset button after closing the product handling gates to dismiss the alarm.

2.10.4 Safety Gates and Doors

The machine is equipped with safety gates and doors that prevent access to the mold, clamp and product handling areas. The gates and doors feature transparent panels for viewing the production area and a series of limit switches for each that trigger an alarm when the gates or doors are opened.

Figure 2-8 Using the Emergency Stop Button

1. Pushing the Emergency Stop Button 2. Resetting the Emergency Stop Button

1 2

Figure 2-9 Gate Reset Button

Mechanical Safety Device (If Equipped) 23


2.10.5 Mechanical Safety Device (If Equipped)

The mechanical safety device inserts a pin into the clamp stroke column when the front safety gate is opened. This prevents unsafe movement of the moving platen while the mold area is accessible to personnel.

2.10.6 CEN Valve

The CEN valve prevents system hydraulic pressure from reaching the clamp, stroke, injection and ejection cylinders when either the safety gates or doors are opened. Limit switches monitor the position of the gates and activate the CEN valve when any gate is opened.

Figure 2-10 Safety Gates (Typical)

1. Limit Switch (Typical) 2. Product Handling Gate 3. Front Gate

1

3

2

Figure 2-11 Mechanical Safety Device (Typical)

1. Mechanical Pin 2. Mold Stroke Column

1

2


24 Automatic Dump Valve

2.10.7 Automatic Dump Valve

The automatic dump valve discharges all system pressure from the accumulator in a reasonably short period of time when the Pump Motor Off key is pressed on the HMI. This makes sure no hydraulic pressure is stored in the system when the machine is shut down.

2.10.8 Manual Dump Valve

The manual dump valve is a backup safety device used to manually relieve hydraulic pressure in the system. Before servicing the hydraulic system, always turn the manual dump valve counter-clockwise to discharge any stored hydraulic pressure.

2.10.9 Purge Guard

The purge guard protects the operator from molten resin that can be sprayed from the injection nozzle. Limit switches monitor the purge guard and trigger an alarm when the purge guard is opened.

Figure 2-12 Manual Dump Valve (Typical)

1. Power Manifold Assembly 2. Manual Dump Valve

1

2

WARNING!The machine is designed to keep the injection nozzle tip safely within the purge guard during operation and purging. Operating or purging the machine outside of this guarding is prohibited and can result in uncontained molten resin spray, causing serious injury or death.

Electrical Cabinet Door Interlocks and Override (UL only) 25


2.10.10 Electrical Cabinet Door Interlocks and Override (UL only)

NOTE: This safety device is available only on machines designed to Underwriters Laboratory (UL) standards.

Each door on the electrical cabinet is equipped with an interlock switch that disables power to electrical components when one of the doors is opened.

For troubleshooting purposes, the interlock system can be overridden to maintain power while the doors are open.

To override the interlock system, do the following:

1. Insert the interlock override key into the key switch.

2. Turn the key switch to the OFF position. The Door Interlock Off indicator push-button light will light up when the interlock system is disabled.

NOTE: The Door Interlock Off indicator push-button light can be pressed at any time to test the light. Replace the bulb immediately if it does not light up.

Figure 2-13 Purge Guard (Typical)

1. Purge Guard

1

Figure 2-14 Interlock Switch


26 Electrical Cabinet Door Interlocks and Override (UL only)

Figure 2-15 Electrical Cabinet Door Interlock

1. Door Interlock Off Push-Button Light 2. Door Interlock Key Switch 3. Electrical Cabinet

1 2

3

Operator Manual v 2.6 April 2012 Specifications

27

Chapter 3 Specifications

This chapter details the pertinent technical specifications required by an operator.

NOTE: Husky reserves the right to change specifications without prior notice.

Specification Value

Hydraulic Oil Operating Temperature (Minimum to Maximum) 47 to 53 C (117 to 127 F)

Pneumatic Inlet Pressure 7.9 to 10.3 bar (115 to 150 psi)

Minimum Permissible Temperature for Plasticizing 182 C (360 F)

Maximum Permissible Temperature for Plasticizing 415 C (779 F)


28

Operator Manual v 2.6 April 2012 Human Machine Interface (HMI)

Access Rights 29

Chapter 4 Human Machine Interface (HMI)

This chapter describes the basic features, functions and use of the Human Machine Interface (HMI). The HMI is used by the operator to control and monitor the machine.

4.1 Access Rights

Access to various HMI and machine functions is controlled through access rights assigned to individual users. Access rights are added, defined and removed by personnel with Administrator level profiles on the machine.

An administrator can assign a user one or more rights depending on the users access requirements.

IMPORTANT!Access to select features of the HMI is controlled through user access rights set by an administrator. Some screens and features described in this chapter may not be exactly as displayed on the HMI for your machine.

Figure 4-1 Human Machine Interface (HMI)


30 Default User Name and Password

The user types and associated access rights are described as follows:

NOTE: Some fields and buttons on the HMI screen will disappear or be greyed out if the user logged into the HMI has insufficient access rights.

4.2 Default User Name and Password

It is the responsibility of the user with Administrator access to setup other users and assign them access rights based on their requirements. Until this is done, a default Operator profile can be used.

The user name and password for the default Operator profile is as follows:

Rights

View

Onl

y

Slid

er

Oper

ator

Proc

esso

r

Mai

nten

ance

Adm

inist

rato

r

View operator screens Adjust sliders, plus limited access to certain machine functions Change operator setpoints Change process setpoints Calibrate machine Switch languages and units Manage machine users and rights Load mold setup parameters Change machine Change date and time formats Set shifts Install molds

Default User Name operator

Default Password 123

IMPORTANT!The default user name and password for the default Operator profile should be changed immediately after commissioning the machine.

Logging On 31


4.3 Logging On

Access to the HMI and machine functions requires either a valid username and password, or a valid datakey. This section describes how to log on to the HMI using either method.

4.3.1 Logging On With a Datakey

Two datakeys are provided by Husky with each machine. One key is for administrators only, while the other is for operators. Datakeys are used to save important user-specific information such as the user name, password, language setting and other configurations.

If a datakey is available, insert it into the datakey port on the HMI. You will be automatically logged in to the HMI and all configuration settings saved on the datakey will be applied.

NOTE: The datakey must remain in the HMI to access machine functions. You will be logged out if the datakey is removed.

4.3.2 Logging On With a Username and Password

To login through the HMI, do the following:

1. Touch the User Log On/Off button on the toolbar at the top of the screen to open the User Log On dialog box.

Figure 4-2 Datakey

Figure 4-3 User Log On/Off Button


32 Logging Off

2. Enter your username in the User Name field.

3. Enter your password in the Password field

4. If the machine is connected to a network, enter the network account in the Domain field. Otherwise, leave the field blank.

5. Touch the Accept button to log on or touch the Exit button to cancel.

4.4 Logging Off

To log off the HMI, touch the User Log On/Off button on the toolbar at the top of the screen. When a confirmation dialog box is displayed, press Yes to log off.

Figure 4-4 User Log On Dialog Box

1. User Name Field 2. Password Field 3. Domain Field 4. Accept Button 5. Exit Button

Figure 4-5 User Log On/Off Button

General Layout 33


4.5 General Layout

The front panel of the HMI consists of a touch-sensitive display screen and a series of control/function keys.

Figure 4-6 Human Machine Interface (HMI) Layout

1. Sidebar Function Keys 2. Cycle Mode Keys 3. Main Screen 4. Robot Function Keys 5. Pump Motor Keys 6. Control Keys 7. Screen Keys 8. Manual Function Keys


34 Sidebar Function Keys

4.5.1 Sidebar Function Keys

The sidebar function keys are used to monitor process values and control select machine functions during operation. The keys are positioned on both sides of the HMI display screen.

The Sidebar Function Group key selects the group of sidebar functions and process values that are displayed. The Sidebar Function keys activate the individual sidebar functions within the group.

The sidebar functions display either process values or enable functions. Process value icons display real-time values during operation about a specific component, such as high or low values for electrical components. Function icons activate specific functions, such as opening an air gate or closing the mold.

NOTE: Icons can be removed from or added to the group using the User Configuration screen. New user configured function groups can also be created and linked to a specific user profile for future use.

4.5.1.1 Accessing the Function Groups

To display a function group, press the Sidebar Function Group key until the icon for the function group appears at the top of the sidebar. Alternatively, you can also scroll through the function groups until you find the Function Group Selector icon and then open the function group using the Sidebar Function keys.

All related functions in a group are displayed next to the Sidebar Function keys below the function group icon.

Figure 4-7 Sidebar Function Keys

1. Sidebar Function Group Key 2. Sidebar Function Group Icon 3. Sidebar Function Key 4. Sidebar Function Icon

Standard Sidebar Function Groups and Sidebar Icons 35


4.5.1.2 Standard Sidebar Function Groups and Sidebar Icons

The following is a list of the standard sidebar function groups and their associated icons.

Sidebar Function Groups Sidebar Functions

Machine Ejector Auto

Screw Change Screw Released

Screw Engaged

Injection Jog Forward

Injection Jog Back

Injection Monitoring Injection Position

Injection Speed

Injection Pressure

Screw RPM

Air Air Auto

Air Manual On


36 Standard Sidebar Function Groups and Sidebar Icons

Product Handling Tooling Plate In

Tooling Plate Out

CoolPik Horizontal

CoolPik Vertical

Tooling Plate Clear Parts

CoolPik Clear Parts

Conveyor Forward

Conveyor Back

CoolPik Part Transfer

Tooling Plate Cooling On

Tooling Plate Vacuum On

Sidebar Function Groups Sidebar Functions

Function Group, Function and Process Value Icons Explained 37


4.5.1.3 Function Group, Function and Process Value Icons Explained

The following is a description of basic function group, function and process value icons used in the sidebars.

4.5.2 Cycle Mode Keys

The Auto Cycle, Semi Cycle and Manual Cycle keys are used to select one of three available cycle modes for the machine. The cycle modes include automatic, semi-automatic and manual.

Once automatic cycle or semi-auto cycle is selected, the Cycle Start key can be used to start the cycle.

NOTE: The Cycle Start key is not required to run the machine in manual cycle mode.Each key has an LED indicator in the top left corner that turns on when the cycle mode is selected.

Icon Type Description

Function Group

Each function group icon shares the following characteristics:

1. A folder symbol

2. A symbol representing the function group type

3. A symbol representing the function type

4. A number indicating the number of functions the group contains

Function Each function icon shares the following characteristics:

1. A symbol that changes color when the function is active


3. A symbol representing the function type

4. The function number

Process Value

Each process value icon shares the following characteristics:

1. A process value symbol


3. A numeric value that increases/decreases during machine operation

4. The unit of measure for the process value


38 Robot Function Keys

NOTE: On systems that have an integrated conveyor belt, the conveyor will run automatically when the Auto Cycle or Semi Cycle keys are pressed.

4.5.3 Robot Function Keys

If the machine is equipped with a product handling robot, the Robot Home and Robot Enable keys can be used to activate and control the position of the robot. An LED indicator in the top left corner of the keys will turn on when the keys are active.

4.5.4 Pump Motor Keys

The Pump Motor On and Pump Motor Off keys start and stop the pump motor. An LED indicator in the top left corner of the keys will turn on when the keys are active.

Key Name Function

Cycle Start Starts the machine cycle after a cycle mode is selected. The LED indicator will flash when the machine is ready to start.

Auto Cycle Selects the automatic cycle mode.

NOTE: The LED indicator will flash if an alarm is triggered that must be cleared before the machine can cycle.

Semi Cycle Selects the semi-automatic cycle mode.


Manual Cycle Selects the manual cycle mode.


Key Name Function

Robot Home Returns the robot to the home position.

Robot Enable Runs the robot during machine operation.

Main Screen 39


4.5.5 Main Screen

The main screen is a touch-sensitive display panel used to monitor machine functions and modify operating parameters. The touch-sensitive feature allows the user to touch parts of the screen to navigate between screens, change values, select options and more.

NOTE: Use the screen keys to change the displayed screen group. Refer to Section 4.5.6 for more information.

The screen area consists of the following parts:

Message Bar Toolbar Tabs Status Bar Sidebar Icons

Key Name Function

Pump Motor On

Turns on the pump motor.

Pump Motor Off

Turns off the pump motor.

Figure 4-8 Main Screen

1. Message Bar 2. Toolbar 3. Tabs 4. Status Bar 5. Sidebar Function Icons

1

2

3

4

5


40 Message Bar

Message Bar

The message bar displays the most current alarm message.

Toolbar

The toolbar displays icons for common administrative and control functions, as well as the icon for the currently displayed screen group.

Tabs

When selected, each tab under the toolbar displays a screen belonging to the screen group.

Status Bar

The status bar displays select machine status information for quick reference.

Sidebar Icons

The sidebar icons represent machine functions or process values. Refer to Section 4.5.1 for more information.

Figure 4-9 Toolbar

1. Current Screen Group 2. Language Selection 3. Screen Capture 4. Administrator 5. Calibration Selector 6. Machine Mode Selector 7. Alarm Horn Off 8. HMI Configuration 9. User Log On/Off 10. Online Documentation

Figure 4-10 Status Bar

1. Current Cycle Mode 2. Machine Cycle Time 3. Oil Temperature 4. Current User Name 5. Current Date 6. Current Time

1 2 3 4 5 6 7 8 9 10

IMPORTANT!The thermometer in the oil temperature area is color coded as follows:

Blue = Low Green = Normal Red = High

Screen Keys 41


4.5.6 Screen Keys

The screen keys display the various screen groups on the HMI. There are nine main screen keys and three programmable screen keys (F10, F11 and F12) that may be used when necessary for optional auxiliary equipment.

Each screen group can contain a series of screens, accessible by touching the tabs near the top of the main screen.

NOTE: Some screen keys are for optional equipment or software. The screen key will be disabled if the related option is not installed on the machine.

4.5.7 Manual Function Keys

The manual function keys activate specific functions when the machine is in manual cycle mode. Each key must be pressed and held to enable a function.

Each manual function key has an LED indicator that turns on when the function is enabled. The LED indicator will flash when the function is completed.

Figure 4-11 HMI Screen Keys

1. Alarms Key 2. Machine Key 3. Production Key 4. Clamp Key 5. Mold Function Key 6. Injection Key 7. Heats Key 8. Product Handling Key 9. SPC Key 10. Programmable Keys

1 2 3 4 5 6 7 8 9 1010

Figure 4-12 Manual Function Keys

1. Mold Open Key 2. Mold Close Key 3. Unclamp Key 4. Clamp Up Key 5. Ejector Back Key 6. Ejector Forward Key 7. Mold Cooling Key 8. Valve Gate Operation Key 9. Inject Key 10. Screw Rotate Key 11. Carriage Forward Key 12. Carriage Back Key

CAUTION!When using the Clamp Up key, make sure the mold is closed before applying tonnage.


42 Manual Function Keys

[1] The optional nozzle shutoff valve will open if equipped.

Key Name Function

Mold Open Opens the mold

Mold Close Closes the mold

Unclamp Disengages the clamp lock mechanism and retracts the clamp piston

Clamp Up Extends the clamp piston and engages the clamp lock mechanism

Ejector Back Retracts the ejector

Ejector Forward

Extends the ejector

Mold Cooling Opens and closes the mold cooling water valve

Valve Gate Operation

Opens and closes the valve gates in the mold

Inject Moves the injection piston and screw forward[1]

Screw Rotate Rotates the plasticizing screw

Carriage Forward

Moves the injection carriage forward

Carriage Back Moves the injection carriage back

Control Keys 43


4.5.8 Control Keys

Control keys are used to navigate through the HMI screens, escape dialog boxes and enter values.

4.5.9 Common Screen Elements

The following describes common tools and buttons that may be found on various screens.

4.5.9.1 Alphanumeric Touchpad

The alphanumeric touchpad is a touch-sensitive keyboard for entering text. It displays whenever the user presses an alphanumeric input field, such as those found in the logon screen.

The touchpad is used like a regular keyboard. Touch the numerals and characters as required and then touch the Enter key to apply the new text. The touchpad will close automatically once the value is entered.

The touchpad also features buttons for entering common text or symbols. For example, the Husky button enters the word Husky in the display area.

Key Name Function

Previous Screen

Opens the group of screens previous to the one currently displayed.

Next Screen Opens the group of screens following the one currently displayed.

Escape Exits dialog boxes.

Enter Accepts changes or applies values entered using the numeric or alphanumeric touchpads


44 Numeric Touchpad

4.5.9.2 Numeric Touchpad

The numeric touchpad is a touch-sensitive keyboard for entering numeric values. It displays whenever the user presses a numeric input field.

The touchpad is used like a regular keyboard. Touch the numbers as required and then touch the Enter key to apply the new value. The touchpad will close automatically once the value is entered.

Alternatively, the numeric value can be increased or decreased incrementally using the Increase Value or Decrease Value buttons.

NOTE: On the screen behind the numeric touchpad, the background of the numeric input field being changed will turn yellow to indicate it is the field being edited.

Figure 4-13 Alphanumeric Touchpad

1. Field Name 2. Display 3. Touch Sensitive Buttons 4. Enter Button 5. C Button 6. Button 7. Husky Button 8. Space Button 9. Clear Button 10. Cancel Button

Common Buttons 45


4.5.9.3 Common Buttons

Many HMI screens contain similar buttons that can be used to perform specific functions. The following is a list of common buttons and their general functions.

Figure 4-14 Numeric Touchpad

1. Field Name 2. Display 3. Clear Button 4. Touch Sensitive Button 5. Exit Button 6. Help Button 7. Enter Button 8. Increase Value Button 9. Value Range Indicator 10. Decrease Value Button

Button Function

The Exit button is used to close dialog boxes

The Information button is used to display additional information about a particular function or screen element

The Expand View button is used on select screens to open a dialog box containing additional controls and values

The More button opens a dialog box containing additional controls and values

The Recycle button is used to delete selected items

The Stop button is used to end a machine process or calibration function

The Help button is used to display the online documentation


46 Setting the Machine Mode

4.6 Setting the Machine Mode

The Machine Mode Selector on the toolbar allows the user to set one of six modes for the machine. The modes allow the machine to operate with some functions enabled or disabled, depending on the type of operation being performed. Refer to Table 4-1 for more information.

To select a function mode, do the following:

1. Touch the Machine Mode Selector button on the toolbar to display the function mode icons. Refer to Figure 4-15.

2. Select the desired mode.

The Reset button is used to return all screen settings and values to their original, default values

The Accept button is used to confirm changes made to the HMI

The Cancel button is used to cancel changes made to the HMI

Button Function

Figure 4-15 Machine Mode Selector

1. Machine Mode Selector 2. Normal Cycle 3. Dry Cycle 4. Auto Purge Cycle 5. Mold Set Cycle 6. Screw Change Cycle 7. Unload All Pumps Cycle

1

2

3

4

5

6

7

Generating On-Demand and Scheduled Reports 47


4.7 Generating On-Demand and Scheduled Reports

The following procedures describe how to generate reports on-demand and at scheduled intervals. Reports provide important information about machine events and any changes that have been made to the HMI settings in a given time period.

For more information about the types of reports that can be generated, refer to Section 4.7.1.

NOTE: Operator, Processor, Maintenance or Administrator level access rights are required to perform the following procedures.

4.7.1 Report Types

The following report types can be generated through the Reports Selection screen:

Table 4-1 Machine Cycle Modes

Mode Icon Description

Normal Use Normal mode to operate the machine under normal conditions.

The Semi Cycle, Auto Cycle and Manual Cycle keys are functional when this mode is selected.

Dry Cycle Use Dry Cycle mode to disable the injection unit and cycle the clamp.


Auto Purge Use Auto Purge mode to disable the clamp unit and automatically purge the injection unit.


Mold Set Use Mold Set mode to operate the machine at reduced speeds and pressures during mold installation.

Only the Manual Cycle key is functional when this mode is selected.

Screw Change Use Screw Change mode to operate the extruder motor/gearbox at reduced speed when removing the plasticizing screw from the injection barrel.

Only the Manual Cycle key is functional when this mode is selected.

Unload All Pumps

Use Unload All Pumps mode to direct flow from the hydraulic pumps to the hydraulic tank at low pressure.

None of the cycle mode keys are functional when this mode is selected.


48 Generating On-Demand Reports

4.7.2 Generating On-Demand Reports

To generate on-demand reports, do the following:

1. On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

2. In the On Demand Schedule area, select the check box for the desired report. Multiple reports can be selected at the same time. Refer to Section 4.7.1 for a description of each report type.

Report Types Description

Cycle Interruption Report Lists the number of cycle interruptions or machine state changes, the duration of each, the message displayed, and the response time.

Setpoint Change Report Lists all setpoint changes including the original value, the new value, the unit of measure, and the reason (if applied).

Machine Events Report Lists all types of machine events in chronological order including the type, the name of the component where the event originated, a description of the event, and the reason (if applied).

Figure 4-16 Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

1

4

5

2

3

10

11 12 7

8

9

6

Enabling Scheduled Reports 49


3. In the Period area, select the time period to capture in the report.

4. Touch the Generate Report button. A report for each report type selected is generated one after the other.

To view the report(s), refer to Section 4.7.4.

To print the report(s), refer to Section 4.7.5.

4.7.3 Enabling Scheduled Reports

To enable scheduled reports, do the following:

1. On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

2. In the On Schedule area, select the check box for the desired report. Multiple reports can be selected at the same time. Refer to Section 4.7.1 for a description of each report type.

3. In the Schedule area, do the following:

a. Select the check box for each day of the week the schedule(s) should be generated.

b. Enter the time of day the schedule(s) should be generated.

4. Select the Enable Scheduled Reporting check box.

To view the report(s), refer to Section 4.7.4.

Figure 4-17 Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

1

4

5

2

3

10

11 12 7

8

9

6


50 Viewing Reports

To print the report(s), refer to Section 4.7.5.

4.7.4 Viewing Reports

To view on-demand or scheduled reports, do the following:

1. On the HMI, press the Alarms key and touch the Report View tab to display the Report View screen.

2. Select the type of report to view. Refer to Section 4.7.1 for a description of each report type.

3. Touch either the View On-Demand Report or View Schedule Report buttons. The report is displayed in the report window and the date range is displayed Reporting Period field.

4. To print the report after reviewing it, touch the Print button.

4.7.5 Printing Reports

The following procedures describe how to print on-demand and scheduled reports.

NOTE: To print a report after viewing it, refer to Section 4.7.4 for more information.

Figure 4-18 Report View Screen

1. View On-Demand Report Button 2. View Scheduled Report Button 3. Print Button 4. Reporting Period Field 5. Report Window

4

5

1 2 3

Printing On-Demand Reports 51


4.7.5.1 Printing On-Demand R

husky hypet 400

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