operating instructions product line ecopower...

OPERATING INSTRUCTIONS

Read before using the injection moulding ma-chine and keep nearby for reference.

PRODUCT LINE EcoPower B6

EP6GBV00 0510

Subject to technical changes without prior notice.We shall not accept any liability for damage caused by printing errors.

Wittmann Battenfeld GmbH

Wr.Neustädter Straße 81 • 2542 Kottingbrunn • Österreich

Tel. +43 (0) 2252 404-0 • Fax +43 (0) 2252 404-6102

[email protected]

www.wittmann-group.com

DIN EN ISO 9001

TECHNOLOGY working for you.

Operating Instructions

Production line

Machine model

Control system type

Machine number

Year of manufacture

Number of instruction manual

Date of issue

EcoPower

110 / 350

UNILOG B6

132331-100

2010

EP6GBV00_0510

17.05.2010

Contact

Chapter 1 ........................................Preface

Chapter 2 .......................................... Safety

Chapter 3 ............................. Technical data

Chapter 4 ................. Transport / Installation

Chapter 5 ........................... Mould mounting

Chapter 6 ................. Structure and function

Chapter 7 ........................................Start-up

Chapter 8 ................................ Maintenance

Chapter 9 ............................. Spares / Plans

Chapter 10..................Special descriptions

Chapter 11 ...................................... Contact

Table of Contents

EP6GBI2AEP6DEI2A0510WT Index - 1

1 ......................................................................................................Preface1.1.......................................................................................................................................................... Introduction1.2..............................................................................................................................................Area of Applicability 1.3........................................................................................................................................ Explanation of symbols1.4..............................................................................................................................................................Copyright1.5...............................................................................................................................................Transfer Certifi cate1.6...................................................................................................................................... Certifi cate of Conformity

2 .........................................................................................................Safety

2.1................................................................................................................................................ Safety regulations2.1.1.......................................................................................................................................... General information2.1.2......................................................................................................................................................... Installation2.1.3..............................................................................................................................Operation and maintenance2.1.4............................................................................................................. Safety instructions affecting personnel2.1.5...................................................................................................... Safety regulations Hydraulics / pneumatics2.1.6..................................................................................... Safety regulations for the Modular Airmould® System2.1.7.....................................................................................................Safety regulations for moulding compounds2.1.8..........................................................................................................................Safety regulations for electrics2.1.9................................................................................ Safety regulations for changing nozzle, screw and barrel2.1.10..................................................................................................................... Safety instructions Environment2.2.................................................................................................................................... Table for risk assessment

3 ........................................................................................... Technical data

3.1 ............................................................................................................................................................... General3.2....................................................................................................................................................... Hydraulic unit3.3.................................................................................................................................................. Electrical system3.4 ...................................................................................................................................................... Water system3.5..................................................................................................................................................... Pump capacity3.6.................................................................................................................UNIFEED material feed unit (optional)3.7 ........................................................................................................................................................ Injection unit3.8....................................................................................................................................................... Clamping unit3.9................................................................................................................................................ Mould dimensions3.10 .............................................................................................................. Conversion table for injection weights3.11 ................................................................................................................Weights of screws and screw barrels 3.12 ............................................................................................................................ Tightening torques of screws3.13.....................................................................Tightening torques of the fi xing screws for the screw barrel head3.14....................................................................................................... Servo motors with fl ange cooling (optional)3.14.1........................................................................................................................................ Design and function3.14.2......................................................................................................................................................... Flow rate3.14.3.......................................................................................................................................Cooling water quality3.14.4........................................................................................................................ Cooling water system settings3.14.5.................................................................................................................... Cleaning of the cooling channels3.15.......................................................................................................................................................... Feed zone3.16.............................................................................................................................. Mould mounting dimensions3.17........................................................................................................................ Foundation and installation plan

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4 .............................................................................. Transport - Installation

4.1................................................................................................................................................................ General4.2................................................................................................................................................................ Storage4.3.............................................................................................................................................................Unloading4.4......................................................................................................................................... Installation layout plan4.5 ............................................................................................................................................... Machine transport4.6............................................................................................................................................. Machine installation4.7...........................................................................................................................Transport equipment and tackle4.8 ...........................................................................................................................Removal of preservation agent4.9.......................................................................................................................................... Alignment of machine4.10................................................................................................................................................Hydraulic system4.10.1...............................................................................................................................................................Filling4.10.2.................................................................................................................. Commissioning of hydraulic pump4.10.3..............................................................................................................................................Bleeding system4.10.4...................................................................................................................................... Core puller (optional) 4.11 ..................................................................................................................................................... Water system4.11.1 ................................................................................................................................................... Water quality4.11.2 ................................................................................................................................Cooling water connection4.11.3 ...........................................................................................................................Oil cooling system (optional)4.11.4 ........................................................................................................................................ Heating/cooling unit4.12..............................................................................................................................................Pneumatic system4.12.1............................................................................................................................ Compressed air connection4.12.2............................................................................................................................UNIFEED material feed unit 4.13...........................................................................................................................................Electrical equipment

5 ........................................................................................ Mould mounting5.1 ......................................................................................................................................................... Preparation5.2................................................................................................................................................... Mould mounting5.3.................................................................................................................. Quick-action mould mounting system5.4................................................................................................... Magnetic quick-action mould mounting system 5.5............................................................................................................................................................. Interfaces5.6................................................................................................................................ Checking the safety devices5.7 ................................................................................................................................... Test run and interlock test

6 .................................................................................. Design and function

6.1....................................................................................................................................................... Clamping unit6.1.1.........................................................................................................................................Technical description6.1.2............................................................................................................................. Lubrication of toggle system6.1.3................................................................................................................................... Central lubrication pump6.1.4................................................................................................................................................. Turn-out device6.1.5................................................................................................................................. Mechanical closing guard6.2......................................................................................................................................................... Injection unit 6.2.1.........................................................................................................................................Technical description 6.2.2............................................................................................................................................. Centring of nozzle6.2.4.................................................................................................................................................. Nozzle change6.2.4.1................................................................................................................Basic conditions for nozzle change6.2.4.2.................................................................................................................................Changing “open” nozzle6.2.4.3........................................................... Changing Herzog type SHP needle shut-off nozzle spring-controlled6.2.4.4.................................................................................................Changing Fuchslocher needle shut-off valve 6.2.4.5......................................................................................... Changing Herzog type HP needle shut-off nozzle...............................................................(pneumatically or hydraulically operated) with integrated control cylinder

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6.2.4.6 Changing Herzog type BHP bolt shut-off nozzle (pneumatically controlled) with integrated control cylinder6.2.4.7........................Changing Herzog type HP needle shut-off nozzle (pneumatically or hydraulically operated) 6.2.4.8............................... Changing Fuchsloser needle shut-off nozzle (pneumatically or hydraulically operated) 6.2.4.9........................................................ENG pneumatic needle shut-off nozzle with integrated control cylinder6.2.5................................................................................................................ Dismantling the screw barrel / screw6.2.5.1 .........................................................................................................................................Dismantling screw 6.2.5.2 .........................................................................................................................Dismantling the screw barrel 6.2.8.................................................................................. Cleaning the screw barrel (change of injection material)6.2.9............................................................................................................. Removal with high-grade polyethylene6.2.10.........................................................................................................Material removal with cleaning granules6.2.11 ............................................................................................................................... Cleaning the screw barrel6.2.12........................................................................................................................................................... Storage6.3..................................................................................................................................................Hydraulic system6.3.1............................................................................................................................................................. General6.3.2..........................................................................................................................................................Pump unit6.3.3................................................................................................................................................... Hydraulic tank6.3.4....................................................................................................................................................... Return fi lter6.3.5...........................................................................................................................................Oil cooler (optional)6.3.6............................................................................................................................ Indicating and control device6.3.7.............................................................................................................................................. Pressure settings6.3.8.................................................................................................................................................. Speed settings6.3.9......................................................................................................................................... Hydraulic core puller6.4................................................................................................................................................Pneumatic system6.4.1..............................................................................................................................UNIFEED material feed unit6.4.2....................................................................................................................................... Pneumatic core puller6.5...............................................................................................................................................................Airmould6.7.............................................................................................................................................. UNILOG B6 control6.7.1.......................................................................................................................................... General information6.7.2.....................................................................................................................................................Control panel6.7.3................................................................................................................................. Explanation of the picture6.7.4................................................................................................................................................Saving / Printing6.7.5..........................................................................................................................................Control components

7 .................................................................................................. Operation

7.1............................................................................................................................................. General information7.2....................................................................................................................................................... Initial start-up7.3 ............................................................................................... Starting the machine after EMERGENCY STOP7.4........................................................................................................................... Checking the nitrogen pressure7.5...................................................................................................................................... Test run without material7.6....................................................................................................................................Filling the material hopper7.7........................................................................................................................................... Test run with material7.8............................................................................................................................................................. Operation7.9 .................................................................................................................................Shutting down the machine7.10 .......................................................................................................................................... Extended shutdown7.11 .........................................................................................................................................Shut down procedure7.11.1 .................................................................................................................................... Dismantling the mould7.11.2 ............................................................................................................... Further measures for shutting down7.11.3 ....................................................................................................................... Emptying the hydraulic system7.11.4 ................................................................................................................. Emptying the cooling water supply7.11.5 .......................................................................................................... Evacuating the compressed air system7.11.6 .............................................................................................................................................. Other measures7.11.7 ...................................................................................................................Disconnecting the electric system7.12..............................................................................................................Measures after an extended shutdown7.13...................................................................................................................... Changing the place of installation 7.14............................................................................................................................................................. Disposal

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Contact

8 ............................................................................................ Maintenance

8.1 ................................................................................................................................................ General8.2...................................................................................................... Transport, storage and disposal of lubricants8.3................................................................................................ Disposal of electrical and electronic components8.4........................................................................................................................ Hydraulic fl uid and lubricant table8.5......................................................................................................................................... Maintenance schedule8.6..................................................................................................................................................Hydraulic system8.6.1.........................................................................................................................................................Oil change 8.6.2..........................................................................................................................................Bleeding the system8.6.3........................................................................................................................................ Checking the oil level8.6.4....................................................................................................................................................... Return fi lter8.6.5..............................................................................................................................Changing the fi lter cartridge8.6.6.................................................................................................................................................... Breather fi lter8.6.7............................................................................................................................................................ Leakage8.6.8 ..........................................................................................................................................Oil cooler (optional)8.7............................................................................................................................................................ Hose lines8.7.1........................................................................................................................................................ Service life8.7.2.............................................................................................................................................. Inspection criteria8.8.......................................................................................................................................... Hydraulic accessories8.9....................................................................................................................................................... Water system8.9.1 .................................................................................................................................................... Water quality8.9.2.............................................................................................................................. Closed cooling water circuit8.9.3.................................................................................................................................. Hydraulic oil temperature8.9.4...........................................................................................................................................................Oil cooler8.9.5.............................................................................................................................Cooling water fl ow controller8.10................................................................................................................................................ Electrical system8.10.1....................................................................................................................................................... Filter pads8.10.2...................................................................................................................................................Buffer battery8.11 ..............................................................................................................................................Pneumatic system8.11.1 ............................................................................................................................UNIFEED material feed unit8.11.2 .................................................................................................................................................Air purifi er unit 8.11.3 ................................................................................................................................................. Filter cartridge8.11.4 ............................................................................................................................... Mechanical closing guard

9 ...........................................................................................Spares / Plans

10 ................................................................................ Special descriptions

.............................................................................. Customer Service

Preface

HC4GB0AAHC4DE0AA017WT1 Chapter 1 - 1

1 Preface

1.1 IntroductionThis machine documentation is written with the intention that it should be read, understood andfollowed by all those who will be responsible for this Battenfeld injection moulding machine(referered to as machine hereafter).

The complete documentation should be held close to the machine and be available to operatingand maintenance staff at all times.

Only after reading through thoroughly, especially chapter "Safety" can problems with the machinebe avoided and trouble free operation ensured. It is therefore essential that this operating manualbe made available to the personnel concerned. This should take place before commissioning,because we can take no responsibility for damage and operating faults arising from ignorance ofthis operating manual!

There are facilities for the training of your operating staff in your works or at our factory. Forfurther information, contact the Training Department.

Should you still encounter difficulties, please contact our Customer Service Department or ourLocal Technician or Agent (addresses are given in chapter "Customer Service") who will bepleased to help.

This Operating Manual is valid only for the machine specified on the front cover.

The presentation and content of this manual are subject to technical alteration, as required bycontinuous improvements of the machine and / or its plant components.

1.2 Area of ApplicabilityMachines of this range have been designed as standard for the processing of thermoplastics andoptionally for processing rigid PVC, thermoset plastics, elastomers and LIM (Liquid InjectionMoulding - process for the injection moulding of liquid two part silicone rubbers).

Any other use is regarded as improper. The manufacturer accepts no responsibility for anyresulting damage; the risk is borne entirely by the operator.

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1.3 Explanation of symbolsThe Warning symbol is to be found with all work safety instructions in this operating manualwhere there is a hazard to the health and safety of persons. Follow these instructions and act inthese cases with extreme care. Pass on all work safety instructions to other users. In addition tothe instructions given in this operating manual the general health and safety regulations must beobserved.

Warning and prohibition symbols may be present on the machine. They warn of particulardangers of death or injury to operating and maintanance personnel.

The "Hot surface" sign indicates areas where there is a burning hazard. The user must beprotected 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.

CAUTIONCaution marks those sections with these operating manual where there are instructions orregulations 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 intocontact with electrical equipment and materials. Care must be taken to ensure that theapplicable local electrical safety regulations are followed.

The mandatory symbols, "Use face protection" and "Wear safety gloves", are to be found at themould, mould nozzles of the machine. When the person having access to the mould areacompletely enters the machine (according to EN 201), the mandatory symbol "Wear personalprotective equipment" is additionally to be found at the mould.

They warn of particular dangers of death or injury to operating and maintanance personnel. Theuser must be protected by appropriate personal protective equipment.

Preface

HC4GB0AAHC4DE0AA017WT1 Chapter 1 - 3

The symbol for environmental hazard draws attention to environmental hazards, for instance indisposal of all sorts of materials. When carrying out repair and maintenance work the locallyapplicable laws and decrees have to be complied with.

1.4 CopyrightThe copyright of this operating manual remains with Battenfeld GmbH. This operating manual isintended for assembly, operating and supervisory staff. It contains instructions and diagrams of atechnical nature which may not be reproduced entirely or in part, distributed or used withoutauthorisation for the purposes of competition or conveyed to third parties.

1.5 Transfer CertificateThe transfer certificate enclosed with this operating manual is to confirm the transfer of the IMMand the completeness of the operating manual. After checking, the Transfer Certificate should becompleted, signed and returned to the "Documentation" Department.

1.6 Certificate of ConformityThe Certificate of Conformity is included at the end of this Section.

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Safety

HC4GB0BAHC4DE0BA017WT1 Chapter 2 - 1

2 Safety

2.1 Safety regulations2.1.1 General information

Numerous safety devices on the machine or the robot contribute to safety and accidentprevention. The proprietor is responsible for the efficient operation of the safety devices.

The machine has been designed and built to the currently applicable safety regulations inEuropean Standard EN 201 and is safe to operate. Hazards may still arise from this machine if itis operated by untrained personnel or is used improperly or for an unsuitable purpose.

For safety reasons the control software may not be modified. Any unauthorised modification tothe software will invalidate possible claims of guarantee / warranty.

The regulations on environmental hazards, safety and the prevention of accidents as well as theinternal procedures are always applicable to the running of the machine.

Unless otherwise contractually agreed upon with the manufacturer, the guarding has beendesigned according to safety regulations (EN 201) the for an operation of the machine at groundlevel.

If the machine, without knowledge of the manufacturer, is installed in a pit or surrounded with apedestal, the proprietor is obliged to adhere to the safety regulations according to the EuropeanStandard 201, and especially to EN 294.

Unauthorised modifications and alterations which affect the safety of the machine are notallowed.

Modifications and alterations which affect the safety of the machine as well as all work relating tomaintenance are to be documented in an inspection record which is to be stored for at least tenyears.

Proper use of the machine includes observation of the instructions laid down by the manufacturerfor assembly, dismantling, commissioning, operation and maintenance.

Responsibilites and procedures for all work involving installation, dismantling, modification andmaintenance of the machine are to be recorded in a procedure.

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Safety

The machine has been designed and built according to the currently valid standard DIN EN 292-2so that hazards from noise emission when used properly and with optimised settings are reducedto the lowest possible level.

Before operating the machine with a robot, the safety regulations in the "Robot" operating manualmust be followed without fail.

Before operating the machine with integrated peripheral equipment (e.g. material feeder) thesafety regulations in the appropriate Peripheral Equipment Operating Manual(s) must be followedwithout fail.

Connection and installation of peripheral equipment may only be carried out by authorised skilledtechnician.

The proprietor has to make sure and verify that the operator is aware of the safety instructionsand potential harzards and follows the operating manual at regular intervals.

The installation of a Battenfeld mould-lifting crane may only be carried out by an authorisedskilled technician. The crane may only be used for installing and removing moulds. It is forbiddento linger under the suspended load. The Safe Working Load is shown on the crane’s specificationplate.

Even if the machine is only subject to slight modifications in terms of position it should bedisconnected from any power supply. Reconnect all power supplies according to the operatingmanual before restarting the machine.

If the machine is disposed of to a third party or firm, these operating instructions must be handedover with it. If is recommended to have written confirmation of this.

Safety


2.1.2 InstallationFor installation, dismantling, modification, adaptation, and maintenance, work parts, componentsor the entire machine have to be secured and carefully attached to the lifting gear so as toprevent any dangers from arising. Only use appropriate lifting gear in proper working order withsufficient carrying force. Personnel or other persons must by no means stand or work undersuspended loads.

Loads may only be fastened, secured and transported by experienced, authorised and trainedpersonnel.

The machine may only be lifted using the lifting points described in Chapter "Transport -Installation".

Before installation of the machine the safety measures detailed in DIN EN 292-2, Para. 6.1.2must be complied with.

After electrical installation or maintenance all the applicable safety measures (e.g protective-conductor system, voltage test, insulation test) must be tested according to the Europeanstandard EN60204-Kpt20.

Hazards may arise from this machine during setting if the setting is carried out by untrainedpersonnel 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 sufficientknowledge of material, moulds and the control of the machine and who are familiar with therelevant safety regulations, regulations for the prevention of accidents, directives and generallyapproved rules in technology, e.g. DIN standards.

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Safety

2.1.3 Operation and maintenanceAll work is in principal to be carried out with the machine being idle. The appropriate isolationprocedures must be followed.

Before starting work on the machine its drive and periphery equipment must be secured againstaccidental reconnection, e.g. using a padlock on the main switch.

Before reconnecting the machine the safety devices must always be checked for their properfunction and to be documented by the proprietor.

Before putting into operation after repair it must be verified that all the safety devices are in placeaccording to regulations.

Safety devices may only be removed with the machine switched off and secured againstaccidental reconnection.

If the ejector or core pullers are operated with the safety door open, it must be ensured that thereare no pinching or crushing points on the mould.

Spare parts must meet or exceed the technical specification laid down by the manufacturer.

The operator is responsible for ensuring that the electrical components, motors etc. do not comeinto contact with any liquid.

Carefully clean the environment, especially connections and screw connections before servicingthe plant.

Cleaning materials are classed as flammable liquids, hazardous to health. The manufacturers’instructions are to be followed without fail. Do not use aggressive cleaning agents. Use non-fibrous cleaning cloths.

When using oils, greases or other chemical substances, follow the safety regulations applicableto 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 mustalways be tightened as specified on the table. Check pipework for leaks, loosened screwconnections, chafe marks, and damage. Remedy detected defects immediately.

Safety


2.1.4 Safety instructions affecting personnelAll persons involved with the machine on the proprietor’s premises, whether for installation,dismantling, commissioning, operation, maintenance (inspection, service and repair) must firstread and understand the appropriate operating instructions, especially chapter "Safety". Theproprietor is advised to have this confirmed in writing.

The machine may only be operated, maintained and repaired by authorised, trained personnel.Personnel must have undergone special instruction about possible hazards.

Personnel to be trained, instructed or which has not yet finished the professional training mayonly work at the machine if supervised by authorised, trained and instructed staff.

The operators must wear their hair tied back, close-fitting clothes and must not wear any jewelsincluding rings. There is a danger of injury, e.g. when getting caught.

Responsibilities for installation, dismantling, commissioning, operation, and maintenance mustbe clearly defined and adhered to so that no grey areas arise on the subject of responsibilities forsafety.

For all work involving assembly, dismantling, modifications and maintenance, the machine is tobe switched off at the mains switch and must be secured against accidental switching on. (e.g.by inserting a padlock into the main switch).

All energy supply lines to the machines (e.g. compressed air, pressurised fluids, ...) must beswitched off.

When undertaking work involving installation, dismantling, modification, operation andmaintenance, no flammable liquid may be allowed to come into contact with components whosehigh temperatures could cause a fire and explosion risk.

Let the following components cool down to a safe temperature before carry out any work involvinginstallation, dismantling, modification and maintenance:

• Heating elements and their guardings.

• Temperature control units, their fittings, flow and return lines and their mounting elements.

• The outside cooling of the screw barrel (option) and / or the barrel throat zone (option),operated with water or heat transfer oil, including all fittings, flow and return lines andmounting elements.

• The internal cooling of the screw (option), operated with water or heat transfer oil, includingall fittings, flow and return lines and mounting elements.

The operator must protect him / herself from burning hazards from the heating elements,temperatur control units and their covers, fittings, flow and return lines and their mountingelements, and the housings of electrical motors by wearing appropriate PPE.

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Safety

The operator has a duty always to use the machine with closed safety gates and guards.

No working method which compromises safety of the machine should be employed.

The operator has a duty to ensure that no unauthorised person works on the machine.

The operator and other personnel may only stand in front of the machine on the operator’s sideduring 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 onthe machine.

The operator is obliged to report at once any alteration in the machine which affects safety. Ifnecessary, the machine should be switched off at once by operating the emergency stop devicesand 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 andmonitoring on the part of the proprietors.

The operator is obliged to observe all safety regulations and danger signs at the machine. Thesesigns must be complete and fully legible.

If components of the machine are located higher than the average body height, climbing aids andworking platforms which meet the legal safety requirements must be used for installation,dismantling, modification, operation, and maintenance. Do not use components of the machineas climbing aid. When working at greater heights, proper equipment for proctection against fallingdown must be worn.

The operator has a duty to ensure that no foreign bodies enter the material hopper, stuffingdevice, or barrel throat.

The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flyingout.

When using mould nozzles (Hot runner nozzle, Mouldmaster nozzles) the operator must ensurethat there are no pinching or crushing points.

The proprietor is obliged to attach corresponding safety labels to moulds (not included in theBattenfeld scope of delivery) which are equipped with mould nozzles. These safety labels mustinstruct the operator to use the appropriate personal protective equipment for all work involvinginstallation, dismantling, modifications and maintenance of mould nozzles (Hot runner nozzle,Mouldmaster nozzles).

When undertaking work involving installation, dismantling, modification, and maintenance ofmould nozzles (Hot runner nozzles, Mouldmaster nozzles), the operator is obliged to wearappropriate personal protective equipment (protection for hands and face, etc.).

Safety


Looking directly into the nozzle area itself is not allowed. Use appropriate aids (e.g. a suitablemirror).

In any work involving operation, installation, dismantling, modification and maintenance, thefollowing potential pinching or crushing hazards may arise:

• Between the safety door and safety door frame on closing the clamping unit’s safetydoor(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 thepurge 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 itbackward and forwards.

Machine with pedestal:

• When opening and closing the power-operated safety gate in the area of the safety gatedrive.

There is a crushing and / or shearing and / or impact hazard in the space for part ejection from:

• Moving parts of the mould area which can be reached through the space for part ejection.

• Falling mouldings.

There is a cutting and shearing hazard at the edge of the filling opening of the hopper when fillingin the melt.

In the area of the Roto feeder head, for the internal cooling of the screw (option), there is a hazardof crushing and / or shearing between the rotating and fixed parts.

For magnetic quick-action mould mounting systems (option), the following hazards in theclamping unit area arise from:

• Magnetic fields, which, when in immediate proximity, may influence sensitive devices suchas cardiac pacemakers, hearing aids, disks, etc.

• The power of the magnetic modules which can uncontrollably magnetise objects (e.g.spanners).

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Safety

2.1.5 Safety regulations Hydraulics / pneumaticsThe machine is designed and built to the currently applicable safety requirements of EuropeanStandard EN 982:1996 and is safe in operation. Hazards can, however, arise from the hydraulicsystem of this machine if it is improperly used by untrained personnel or is used for purposes forwhich it is not designed. For this reasons all work involving installation, dismantling,modifications and maintenance may only be carried out by a skilled hydraulic and / or pneumatictechnician.

Hydraulic technicians are persons who due to specialised training and experience have sufficientknowledge in the field of oil hydraulics and who are familiar with the relevant safety regulations,regulations for the prevention of accidents, directives and generally approved rules in technology,e.g. DIN standards.

Before opening hydraulic and / or pneumatic components and hoses, the hydraulic or pneumaticsystems 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 thehydraulic unit have to be expertly installed and laid. Fittings, length and cross section have tomeet the requirements.

Hydraulic fluids (oils) escaping at high pressure can penetrate the skin and cause severe injury.A physician must be consulted at once as there is also a risk of infection.

All pipework, hoses and screw connections should be checked for leaks and damage visible fromoutside at regular intervals. Remedy damage immediately. Hydraulic oil escaping at highpressure can cause severe injuries and fires.

Hydraulic hoses and hose assemblies have to be replaced at the intervals given in the chapter"Maintenance", even if there are no defects to be detected which affect safety.

Hydraulic hoses and hose assemblies must be protected from damaging external influences.

The safety regulations for hydraulic hoses and hose assemblies to DIN 20066 and EN 201 are tobe particularly carefully observed.

Only hose assemblies with fittings that were either supplied or specified by Battenfeld should beimplemented!

All work involving installation,dismantling, modifications and maintenance of pressure vesselsmay only be carried out by personnel trained in this field.

Safety


Work (repair, connection of a pressure gauge) on a machine with pressure vessels must not becarried out until the hydraulic pressure has been released; i.e. the pressure in the pressurevessels 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 standardsorganisation responsible in the proprietor’s region before being put into operation.

Pressure vessels may only be filled with nitrogen "N2". The use of other gases causes explosionhazards.

Keep the test certificates for the pressure vessels and safety valves in a safe place.

The proprietor is responsible for the proper condition, operation and monitoring of pressurevessels (e.g. regular testing). The relevant pressure vessel regulations can be purchased from theappropriate technical publishers. Addresses can be get from the local technical standardsorganisations.

When disposing of used oil and lubricants the local laws and regulations are to be followedwithout fail. The proprietor is responsible for proper waste disposal.

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Safety

2.1.6 Safety regulations for the Modular Airmould® SystemThe Modular Airmould® System (option) has been designed and built to the currently applicableEuropean Standard EN 292, Part 1 and Part 2, EN 60204 Part 1 and DIN EN 983 and is safe tooperate. Hazards may still arise from the Modular Airmould® System if it is operated by untrainedpersonnel improperly or for an unsuitable purpose. For this reason, all work involving installation,dismantling, modifications and maintenance may only be carried out by personnel trained in thisfield.

The Modular Airmould® System must be relieved from pressure according to the descriptions inthe operating manual for all work involving installation, dismantling, modifications andmaintenance.

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 regulationsaccording to DIN 20066 and EN 201 must also be followed.

Only hose assemblies with fittings that were either supplied or specified by Battenfeld should beimplemented.

Only hose assemblies with fittings which comply with or exceed DIN 20078, Part 9 may be used.

Hose assemblies must be mounted so that:

• Their natural position and movement are not hindered.

• In operation they are not subject to external stresses from tension, torsion or crushing.

• They are protected from external mechanical, thermal and chemical damage.

Never paint hose assemblies.

Hose assemblies must not be bent to a tighter bending radius than the minimum specified by themanufacturer.

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 DIN20066.

After fitting or renewal, hose assemblies must be secured so that any hazard on bursting orblowing off is prevented.

After fitting or replacing hose assemblies, the serviceability is to be checked by a trained andskilled technician.

Safety


Nitrogen pipelines must meet or exceed the minimum requirements of DIN EN 10305-E"Seamless cold-drawn tubes for hydraulic and pneumatic pressure lines" and DIN EN 10025"Hot-rolled plain steel products", material code number 1.0255 (St 37-4).

According to the outside diameter of the pipeline, the bending radius must correspond to DIN2916.

The screw connection parts must meet the minimum requirements of DIN 2353 "Solderless pipeconnections with cutting ring" (Heavy Series S).

Pipe fittings must be designed to DIN 20078 Part 9.

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Safety

2.1.7 Safety regulations for moulding compoundsThe machine is intended exclusively for the processing of moulding compound as stated in thechapter "General information". Any other use is considered improper and any loss damage orinjury 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 nearthe heating of the screw barrel or the internal cooling of the screw barrel (option) and the inletarea 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 faultlesscondition and with undamaged electrics.

When processing moulding compounds which give rise to harmful gases, dusts or vapours, theproprietor of the machine has a duty to provide suitable extraction for the protection of operatingpersonnel.

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 beforeshutting the machine down. Gases are formed if certain types of moulded compounds remain fora longer period of time in out of operation heated shut-off nozzle. These gases can escapeexplosively 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.

Safety


2.1.8 Safety regulations for electricsThe electrical equipment on the machine is designed and built to the currently valid standardsDIN EN 60204-1 and IEC 801-2 and is safe to operate. Hazards can, however, arise from theelectrical system of this machine if it is improperly used by untrained personnel or is used forpurposes for which it is not designed. Thus all work involving installation, dismantling,modification and maintenance may only be carried out by a qualified electrician (as defined in DINVDE 0105 or DIN EN 60204-1).

The electrical equipment may only be connected to a mains supply which corresponds in termsof current type, voltage and frequency to the specifications on the machine’s electrical plate. Theelectrical supply lines must meet the requirements.

The machine must be switched off at the main switch before all work involving installation,dismantling, modification and maintenance. Check the electrical equipment for lack of voltage,then earth it and and short it out.

The mains supply and power heating terminals remain live even when the machine is switchedoff.

The electrical equipment is to be checked at regular intervals. Defects such as loose connectionsor scorched cables must be immediately remedied.

For reasons of safety, the operator must log off from the control unit after finishing the settingmode 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 key-operated switches and kept in a safe place.

Legal requirements and regulations must be followed in all work involving installation, dismantling,modification and maintenance.

Danger by current impact! At sockets with this information sign no portable hand-held electricalappliances (e.g. hand drill) may be attached.

Only attach electrical appliances according to the intended use of the sockets.

Not for hand-held electricalappliances suitably!

No FI-protective circuit!GB

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Safety

2.1.9 Safety regulations for changing nozzle, screw and barrelThe nozzle, nozzle body, screw and screw barrel may be assembled or disassembled by trainedand authorised persons only.

It is absolutely necessary to meet the torque settings (according to the table) of the nozzle andthe nozzle body.

When installing a complete injection unit, only parts supplied or specified by Battenfeld may beused.

When fitting or removing the nozzle, screw or screw barrel it is essential to activate and use themachine without the guarding on the injection unit.

The proprietor therefore has a duty to ensure that the danger zone is adequately protected andthat no unauthorised persons enter this zone.

Before moving the injection or nozzle contact cylinders with their guarding on the injection unitremoved it must be ensured that no tools or other materials are left on the machine.

Whilst moving the injection piston or nozzle contact cylinder with the injection unit guardingremoved, the operator must maintain a safe distance.

Immediately after moving the injection or nozzle contact cylinders with their injection unitguarding removed, the machine must be switched off again and secured against accidentalreconnection.

If proper procedures are not followed during mounting or disassembly or when touching nozzle,screw, screw barrel, or its heating elements, there will be the risk of injury and burning hazards.Wear appropriate personal protective equipment.

When fitting or removing the nozzle, screw or screw barrel, no tools may be used which couldcause damage to these components.

Safety


2.1.10 Safety instructions EnvironmentLubricants and hydraulic oils are environmentally hazardous products. For this reason, the localenvironmental laws and regulations concerning water, building, waste, transport, trade and safetyat work must be observed.

These areas of legislation include the fields of transportation, storage and waste disposal.

Even the strictest compliance with all laws and regulations does not preclude accidents withlubricants. In such cases the appropriate authorities (Water Board, Police, Fire Brigade) must benotified immediately. The amount of lubricant discharged before notification is required varies fromplace to place.

There is therefore a need to make contingency plans for preventive measures in the case of anyincident with oil. This includes the existence of such a plan itself, that sufficient oil absorbingmedium is in stock, that drains can be closed off and that tools and materials are available toprevent the spilled oil from escaping.

Request safety specification sheets according to ISO 11014-1 (safety specification sheet forchemical products) for your products from your lubricant supplier.

These cover:

• Chemical and physical properties.

• Protective measures, storage and handling.

• Measures to be taken in the event of accidents and fires.

When disposing of electrical and electronic components, the local laws and regulations are to beobserved.

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Safety

2.2 Table for risk assessmentReasonably foreseeable inappropriate installation / use

Reasonably foreseeable faults in installation and electrical connection

*) The given measures should only be carried out by trained operators / setters.

Case Hazard Consequence Remedies*)

1

Use of unsuitable materials Overload of the machine; possibly fire or explosion risk, hazard to health due to the emission of hazardous substances

Only if the warnings in the operating manual are ignored

Warnings and allowed material range in the operating manual

2

Use of unsuitable moulds; mould not installed

Overload of the machine, uncertain operating conditions, escape of hot material

Damage to machine components, shortcomings in production

Instructions in the operating manual

3

Guardings are not available and the monitoring switches are disabled

High surface temperatures, moving parts during closing movement

Burning hazard if accidentally touched or during maintenance work, crushing hazard from closing movement.

Warnings, labels, instructions in the operating manual

4Operating error Loss of machine

functionInstructions in the operating manual

Case Hazard Consequence Remedies*)

1Electrical supply (voltage, frequency, cable size)

No proper functioning Permanent machine damage


2 Unsuitable coolant (Water flow rate, pressure)

Blockage, overheating Permanent machine damage


HC6_001.XLS

Technical data

EP6GB0CAEP6DE0CA0510WT Chapter 3 - 1

3 Technical data

This chapter contains all technical data required for the proper installation, commissioning and operation of the injection moulding machine.

3.1 GeneralMachine type / control system see cover page

Machine no. / year of manufacture see cover page

Machine weight (gross/net) see foundation and installation plan

Main machine dimensions see foundation and installation plan

Sound level (DIN EN ISO 3744-46) 68 dB(A)

3.2 Hydraulic unit Hydraulic oil, tank capacity see foundation and installation plan

Oil temperature (min./max.) min. 35°C (95°F) / max. 65°C (149°F)

Switch-on temperature for oil cooling system 45°C (113°F)

3.3 Electrical systemInput power, hydraulic pump see foundation and installation plan

Engine voltage see rating plate

Frequency see rating plate

Screw barrel temperature max. 350 °C ( 662 °F) (optional: 450 °C, 842 °F)

3.4 Water systemCooling water tank: Cooling water inlet Ø 3/4", 10 bar (145 psi)

Cooling water return line Ø 3/4"

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Technical data

3.5 Pump capacity

3.6 UNIFEED material feed unit (optional)Feed capacity

At 6 bar (87 psi) pneumatic pressure, 100 % operation and rated hose diameter 19 mm (0.75"), 4 m (13') of hose installed vertically.

10(33)

20(65)

0

HM_1044.WMF

kg / h

250

200

150

100

50

Hose length m (ft)

Feed capacity PA

30(98)

40(130)

50(163)

60(195)

lb/h

(562)

(450)

(338)

(225)

(112)

Machine type 40 (11) 50 (13) 60 (16) EcoPower 55/130 X EcoPower 110/130 X EcoPower 110/350 X EcoPower 180/350 X 0 EcoPower 180/750 X 0 EcoPower 240/750 X EcoPower 240/1330 X EcoPower 300/750 X EcoPower 300/1330 XX Standard 0 Amplifi ed

Technical data


Air consumption

1 Q at 100 % operation

2 Q at 50 kg (52.16 kg) of material / h

3 Q at 35 kg (80 lb) of material / h

Sound level

250

200

150

100

50

0

Air consumption Qn / min

HM_1046.WMF

5(72)

4(58)

3(44)

7(101)

6(87)

1

2

3

Pneumatic pressure (abs.)bar (psi)

HM _1045.WMF71

70.5

70

69.5

69

68.5

68

Sound leveldB / A

5(72)

4(58)

3(44)

Pneumatic pressure (abs.)bar (psi)

7(101)

6(87)

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Technical data

3.7 Injection unit

EcoPower 55

EcoPower 110

EcoPower 180

Injection unit 130Screw diameter mm 14 18 22 25 30

Screw travel mm 90 110 125

Screw L/D ratio 20 22

Calculated stroke volume cm³ 13,9 28 41,8 61,4 88,4

Specifi c injection pressure bar 3000 3000 2871 2117 1471

Max. screw speed min-1 500 400

Max. plasticising fl ow (PS) 2) g/s 1,7 5 7,2 10,5 15,4

Screw torque Nm 90 150 250

Nozzle travel / nozzle force mm/kN 250 / 40

Injection fl ow out of the machine cm³/s 30,8 50,9 76 98,2 141

Increased injection fl ow out of the machine (optional)

cm³/s 61,6 102 152 196 283

2) according to Battenfeld standard

Injection unit 130 350Screw diameter mm 14 18 22 25 30 25 30 35 40

Screw travel mm 90 110 125 175

Screw L/D ratio 20 22 22

Calculated stroke volume cm³ 13,9 28 41,8 61,4 88,4 85,9 124 168 220

Specifi c injection pressure bar 3000 3000 2871 2117 1471 3000 2823 2083 1591

Max. screw speed min-1 500 400 350

Max. plasticising fl ow (PS) 2) g/s 1,7 5 7,2 10,5 15,4 9,3 13,5 21 33,5

Screw torque Nm 90 150 250 500

Nozzle travel / nozzle force mm/kN 250 / 40 250 / 40

Injection fl ow out of the machine cm³/s 30,8 50,9 76 98,2 141 98,2 141 192 251


cm³/s 61,6 102 152 196 283 196 283 385 503


Injection unit 350 750Screw diameter mm 25 30 35 40 35 40 45 50

Screw travel mm 175 225


Calculated stroke volume cm³ 85,9 124 168 220 216 283 358 442

Specifi c injection pressure bar 3000 2823 2083 1591 3000 2650 2095 1697


Max. plasticising fl ow (PS) 2) g/s 9,3 13,5 21 33,5 19,5 31,1 40,5 49

Screw torque Nm 500 900


Injection fl ow out of the machine cm³/s 98,2 141 192 251 192 251 318 393


cm³/s 196 283 385 503 337 440 557 687


Technical data





Calculated stroke volume cm³ 216 283 358 442 437 540 653 913



Max. plasticising fl ow (PS) 2) g/s 19,5 31,1 40,5 49 37,4 45,2 56 67



Injection fl ow out of the machine cm³/s 192 251 318 393 278 344 416 581


cm³/s 337 440 557 687 525 648 784 1095





Calculated stroke volume cm³ 216 283 358 442 437 540 653 913



Max. plasticising fl ow (PS) 2) g/s 19,5 31,1 40,5 49 37,4 45,2 56 67



Injection fl ow out of the machine cm³/s 192 251 318 393 278 344 416 581


cm³/s 337 440 557 687 525 648 784 1095


EcoPower 240

EcoPower 300

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Technical data

3.8 Clamping unit

EcoPower 55

EcoPower 110

EcoPower 180

Clamping unit EcoPower 55Clamping force / locking force kN 550

Beam clearance mm x mm 370 x 320

Mould installation height mm 150 .... 350

Opening travel mm 250

Max. plate distance mm 600

Ejector stroke / ejector force mm / kN 100 / 25

Dry running time 1) s - mm 1,3 - 2241) according to Euromap 6















Technical data
















EcoPower 240

EcoPower 300

Insulating panels, adapter board with T-groves, magnetic mould quick-clamping systems, etc. reduce the standard mould mounting height. For the applicable mould mounting dimensions, see dimension sheet at the end of this chapter.

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Technical data

3.9 Mould dimensionsMinimum mould size

The design of the clamping plate and the 5-point toggles of the clamping system ensure uniform application of the clamping force with precision force distribution.

These mechanisms can however only work properly, if the moulds are of a minimum size so that the mould clamping plates are not excessively defl ected.

As the defl ection of the mould clamping plates affect the dimensional accuracy of the injection mouldings, the additional load on the mould and the function of the mould in connection with complicated constructions (multiple plate moulds, sliding moulds) strictly adhere to the values specifi ed here in order to prevent excessive loads on the clamping unit and the mould.

The minimum mould dimensions specifi ed in the table (clamping unit) must be adhered to. Also take into account the required clamping force to minimise the load on the moulds and the energy consumption of the unit.

At maximum mould weight, 2/3 of the weight must be mounted on the clamping plate.

Also avoid eccentric mounting and ensure that the moulds are horizontally aligned with the split planes of the mould. Otherwise, the mould as well as the clamping unit might become deformed, which could reduce the service life of the guide and sealing elements.

3.10 Conversion table for injection weightsThe maximum injection weights (g / oz) are calculated by multiplying the calculated stroke volume (cm3 / cu inch) with the above factors. PF and UP are factors used for duroplastic materials.

Material Factor Material FactorABS 0.88 PP + 40% talcum 0.98

CA 1.02 PP + 20% GF 0.85

CAB 0.97 PS 0.91

PA 0.91 PVC hard 1.12

PC 0.97 PVC soft 1.02

PE 0.71 SAN 0.88PMMA 0.94 SB 0.88

POM 1.15

PP 0.73 PF 1.3

PP + 20% talcum 0.85 UP 1.6

Technical data


MaterialScrew diameter Weight

[mm] [inch] [kg] [lbs]

130 - 1330

14 0,55 65 143

18 0,71 65 143

22 0,87 65 143

25 0,98 95 209

30 1,18 95 209

35 1,38 130 287

40 1,57 140 309

45 1,77 155 342

50 1,97 205 452

55 2,17 220 485

65 2,56 245 540

Nominal thread size

Assembly tightening torque - strength class 8.8

[Nm] [lbf ft]M4 3 2

M5 5,5 4

M6 9,5 7

M8 23 17

M10 42 31

M12 72 53

M14 114 84

M16 174 128

M20 340 251

M24 580 428

M27 855 631

M27x2 900 664

M30 1160 856

M33x2 1680 1239

M36 2030 1497

M36x2 2200 1623

M39 2620 1932

M42 3240 2390

M48 4890 3607

3.11 Weights of screws and screw barrels

Weights of screw barrels including screws to be taken into account for screw and screw barrel replacements

3.12 Tightening torques of screwsThe tightening torques of screws that must be tightened with different torques are specifi ed in the spare parts list. Strictly adhere to the prescribed torques.

The tightening torques are based on a friction factor of 0.10 (μmtotal) for untreated, galvanically cadmium-plated screws treated with Molycote. They do not apply to slightly oiled surfaces.

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Technical data

3.13 Tightening torques of the fi xing screws for the screw barrel head

These tightening torques apply to the Allen head screws (1) used to secure the nozzle head (2).

For details on strength class, etc, see spare parts lists.

Standard model

Nominal thread size

Assembly tightening torque - strength class 12.9

[Nm] [lbf ft]M8 35 26

M12 130 96

M16 300 221

M20 550 406

High-temperature heating bands

Nominal thread size

Assembly tightening torque - strength class GB

[Nm] [lbf ft]M8 25 18

M12 90 66

M16 200 148

M20 350 258

1

2

Technical data


3.14 Servo motors with fl ange cooling (optional)

3.14.1 Design and function

1 Fitting

2 Cooling channel in fl ange

In order to operate the motors at a higher torque without causing excessive thermal stress, servo motors with fl ange cooling system are used for plasticizing and injection. The fl ange cooling system consists of U-shaped channels in the fl ange through which the cooling water is fed.

The fl ange cooling system of the servo motors is fed through a separate cooling water circuit, which is controlled by the machine control system through the cooling water valve. The servo motors are cooled in series.

CorrosionTake suitable measures to prevent corrosion or other damage caused by organic or inorganic substances to the water channels in the fl anges. Corrosion can lead to leakage at the hose fi ttings, while deposits prevent proper heat dissipation and can block the channels.

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Technical data

Max. water fl ow rate Aluminium / aluminium alloy m/s 1,8

Brass/bronze m/s 2,4

Steel m/s 6

Rubber/plastic m/s 5

Cooling water quality - guide values Cooling water temperature °C < 30

Min. pH 7

Max. pH 8,5

Min. total hardness mol/ccm 0,5

Max. total hardness mol/ccm 10

Min. carbon hardness mol/ccm 1

Max. carbon hardness mol/ccm 2

Chloride ions (max.) mg/l 200

Sulphate ions (max.) mg/l 325

Nitrates and nitrites (max.) mg/l 50

Ammonia (max.) mg/l 0,5

Iron (max.) mg/l 0,2

Manganese (max.) mg/l 0,1

Galvanic corrosion

Galvanic corrosion occurs when differnt types of metals are in contact with each other and are also in contact with a liquid (electrolyte). The anionic metal thereby releases ions into the liquid, which leads to corrosion. This can be prevented by avoiding direct contact between the metals. As the fl ange of the servo motor is made in aluminium, the hose fi ttings are all made in plastic.

Biological corrosion

Biological corrosion is caused by certain bacteria that cause oxidisation on metal surfaces. This type of corrosion can be prevented by adding antibacterial additives to the water. In addition, turbulence in the water fl ow signifi cantly reduces the occurence of such bacteria or algae deposits.

Deposits

To prevent organic and inorganic deposits, the cooling water must be treated. In this process, certain substances must be removed or their concentration must at least be reduced to a level below a critical value. The main substances that can cause deposits are carbonates and phosphates, and, to a lesser extent, sulphates and silicates. Calcium carbonate deposits are for example caused by the carbonate hardness of the water.

3.14.2 Flow rate

3.14.3 Cooling water quality

Technical data


3.14.4 Cooling water system settingsThe fl ow rate of the cooling water is controlled by the control system.

The temperature is factory-set to 50°C. We recommend that you do not reduce the nominal temperature signifi cantly, as this could result in condensation on cold surfaces.

Compared with the cooling water required for the mould, the amount of cooling water needed for the fl ange cooling is low.

The machine is equipped with three independent thermal fuses for the drives and the servo motors, which halt the machine with an error message in the event of an overload. In the event of an overload error

• Check whether the fl ange cooling system is switched on (nominal temperature 50°C, valve powered)

• Check the cooling water fl ow rate

3.14.5 Cleaning of the cooling channelsDeposits in the cooling channels of the fl ange cooling system can be fl ushed out with a suitable rinsing solution.

We recommend using deconex 25 ORGANAZID produced by Borer Chemie. deconex 25 ORGANAZID is applied in a concentration of 2 to 5% in distilled water. To remove persistent deposits, increase the concentration.

deconex 25 ORGANAZID is biodegradable and thus environmentally friendly. As its main ingredient is citric acid, it does not cause damage to aluminium. The product does not foam. The application temperature should be 20°C or slightly higher. At higher temperatures, the fl ushing effect is improved. The rinsing time is 3 to 5 minutes. After fl ushing with the product, rinse the system thoroughly with water.

When handling deconex 25 ORGANAZID, observe the safety instructions of the manufacturer.

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Technical data

3.15 Feed zoneThe feed zone is water-cooled. The temperature can be set at the screen and must be adjusted to a level that prevents melting of the plastic granules in the feed zone of the screw.

The feed zone includes both plastic fi ttings and metal fi ttings.

3.16 Mould mounting dimensionsSee appendix of this chapter.

3.17 Foundation and installation planSee appendix of this chapter.

Transport - Installation

EP6GB0DAEP6DE0DA0510WT Chapter 4 - 1

4 Transport - Installation

4.1 GeneralAfter delivery of the injection moulding machine, inspect it without delay for damage and completeness of the delivery.

Included with the machine are:

• Operating manual(s)

• Levelling elements (optional).

All keys (for switch cabinet, protective guards, etc.) are attached to the main switch.

We recommend having the machine assembled and installed on site by Battenfeld technicians. The manufacturer shall not be liable for damage caused by incorrect assembly or installation.

The foundation and installation plan are included in chapter „Technical data“. This chapter also contains information regarding the machine weight and dimensions. These must be taken into account when installing the machine on site.

The diagrams in the assembly and installation drawings are simplifi ed.

4.2 StorageThe machine is suitably packaged for safe transport without damage. After acceptance of the delivery from the transport company, install and start the machine without delay.

If the unit is to be stored for a prolonged period of time, contact our customer service department.

4.3 UnloadingTo ensure that the machine works without problems and to protect your warranty cover, it is important that the machine is unloaded properly!Transport and lift the machine only by the transport and loading devices provided and ensure that it is at all times in a horizontal position. Secure the lifting tackle against slipping!Use only nylon straps that of suffi cient length. The use of other lifting tackle might cause damage to the boom.The load capacity of the crane and the lifting tackle must be suffi cient to carry the load of the machine. For weight details, see chapter „Technical data“, foundation and installation plan!Strictly observe the transport plan attached to the machine!

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Ensure that no persons are standing in the danger zone of any suspended load!The machine must be placed on a fi rm and level ground that is able to carry the weight of the equipment.If the machine is placed on uneven ground, it might not work properly or become damaged.

If no suitable level ground is available for the installation of the machine, you must build a horizontal installation platform , following the specifi cations and instructions in the foundation and installation plan in chapter „Technical data“.

If it is not possible to transport the machine by crane to its fi nal location of installation, place the unit with its entire base on a suitable transport vehicle and move it to the location of installation.

4.4 Installation layout planFor details regarding the installation layout and space requirements, see chapter „Technical data“.

For maintenance, allow for a distance of 1.3 m (52") from all sides of the machine to the next fi xed structure.



4.5 Machine transport

The machine is equipped with a transport monitoring system. Please handle the equipment according to the transport instructions. Improper handling might trigger the indicator. If there is no indicator installed or if the indicator has been triggered, please make a note to this fact in the transport documentation.

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For the assembly, dismantling, relocation, adjustment or maintenance, individual components, assemblies of the complete machine must be carefully attached and secured to the lifting tackle to ensure that they pose no danger during transport. Use only lifting tackle and equipment that is suitable for the purpose, free of defects and has the necessary load capacity. Ensure that no persons are standing under suspended loads.The attachment, securing and transport of loads must be carried out by experienced authorised specialist person.Before installing the machine, refer to the safety measured in DIN EN 292, item 6.1.2 and strictly adhere to them.If there are differences between the information in the transport plans and the descriptions and pictures below, always follow the instruction in the transport plans in chapter „Technical data“!

EcoPowerTransport by forklift truck

When transporting the unit by forklift truck, lift it at the lifting points provided as specifi ed in the foundation and installation plan (see chapter „Technical data“).

Transport by crane and lifting tackle

Lift the machine only by the two upper beams of the clamping unit located near the nozzle plate. To do this, lead the lifting tackle under the beams.



Machine weight

4.6 Machine installationThe injection moulding unit must be installed in a dry room that is free of dust and protected against frost. The machine body must be fully placed on the levelling or wedge elements.

Adjustment of the swing elements The swing elements can be adjusted by means of the hex head screw. The height of the swing elements can thereby be adjusted within a range of 59 mm (2.32") to 80 mm (3.15"). To secure the device in the desired height, lock the screw (1) with a hexagon nut (2).

1

2

Machine weight TYPE kg lbs

55/130 3.000 6.615

110/130 4.600 10.143

110/350 4.800 10.584

180/350 6.800 14.994

180/750 7.200 15.876

Type Article Nr. EcoPower 55-180Swing elements NMS 160/M 16 100NE008 8

Article Nr. Type Height Setting range100NE008 NMS 160/M 16 59 21

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4.7 Transport equipment and tackleThe transport equipment and tackle described in this section must be removed prior to commissioning and reattached each time the machine is to be transported!

EcoPower guardThe guards at the clamping side are opened at the operating and rear side of the machine and secured with a rope slung around the machine frame and the handles of the guards.

EcoPower front plate

For transportation, the clamping unit is secured with two Allen head screws (2). They connect the front plate (1) to the machine frame (3) and must be removed before aligning the machine.

1

2

3

4



1

2

4

5

6

7

3

4.8 Removal of preservation agentClean the rust protection grease from all bare metal moving parts and guides (beams, piston rods, etc.) and all uncoated and ungalvanised screws. To do this, use a cold detergent, white spirit, petroleum or a similar chemical and a cleaning cloth.

The supplied small parts such as the screw tips, stop ring, etc. have been preserved by means of immersion. Remove the preservative wax layer.

CAUTIONDo NOT preserve the spindles or remove preservative from them! If required, these parts can be preserved by applying the prescribed operating grease.

CAUTIONPlease note that even a single stroke performed before the preservative is removed can cause damage to the machine, as the preservative might become clogged in the guides, leading to wear!

The cleaning agents listed above are hazardous and fl ammable substances. Observe the manufacturer instructions!

Dispose of the agents and all cleaning cloths contaminated with them according to the applicable statutory waste disposal regulations!

Injection unit 130-13301 Kolbenstangen Düsenandruckzylinder

2 Guide of hopper base

3 Guide rails of injection unit

4 Material feed block

5 Screw barrel, shaft and mount

6 Linear guides of injection drive

7 Screw lock

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Clamping unit 55-3001 Mould clamping surface

2 Guide rails of clamping plate

3 Beams

• Guides and catchers of ejector

• Gears of mould height adjusting unit

• Toothed rack of closing guard

1

23



4.9 Alignment of machineTo align the machine, you need a machine spirit level with an accuracy of 0.1 mm / m (0.004" / 3.281 ‘) and a completely straight measuring rod. In addition, the machine must be equipped with levelling elements / wedges (optional).

Place the machine spirit level (1) on the sliding rails (2) of the clamping unit, using the measuring rod (3). Align the machine in longitudinal and transverse direction to the injection moulding machines to an accuracy of 0.2 mm / m (0.008" / 3.281') by adjusting the levelling

elements / wedges, if necessary.

Injection unit

The nozzle is centred at the factory; after transport, check its alignment and adjust it, if necessary.

• Fill in hydraulic oil; see section „Hydraulic unit“.

• Connect the machine to the electric power supply; see section „Electrical system“.

• Select „Setup“ mode.

• Move the injection unit back until the nozzle is fl ush with the nozzle side of the mould clamping surface.

• Shut down the main switch and secure it against inadvertent switching on.

• For instructions regarding the centring of the nozzle, see chapter „Design and function“.

EP6GB0DAEP6DE0DA




EP6GB0EAEP6DE0EA0510WT Chapter 4.9 - 1

4.10 Hydraulic systemAll work on the hydraulic system must be carried out by a specialist hydraulic technician!

If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

The hydraulic system is depressurised, if the clamping plate, the nozzle and the screw are in one of their end positions. To release any residual pressure, carefully loosen (but not open) one of the hydraulic screw fi ttings. In hydraulic systems with pressure vessels (optional), wait until they have also been fully depressurised. For detailed instructions, see chapter „Maintenance, section „Checking of the hydraulic pressure“.

The main switch must be set to its OFF position and secured against inadvertent switching on.

4.10.1 FillingTo gain access to the oil fi ller (1), open the safety gate at the operating side or remove the front cover.

EcoPower 55 - 300

1

EP6GB0EAEP6DE0EA

0510WTChapter 4.10 - 2


CAUTIONUpon delivery, the hydraulic system of the machine meets the requirements of cleanliness class 17/15/12 according to ISO 4406. If the system becomes contaminated so that it does not meet this standard any longer (e.g. due to the use of an unsuitable hydraulic oil or improper fi lling procedures), the warranty of the system shall be voided!Hydraulic oil contaminated with water is of low quality and must not be re-used!

Fill the hydraulic tank only with the hydraulic oil specifi ed in chapter „Maintenance“. For the required oil volume, refer to the foundation and installation plan (in chapter „Technical data“).

CAUTIONTest the hydraulic oil for water contamination!

Never switch on the machine when it is not fi lled with hydraulic oil. Even short runtimes can cause damage to the hydraulic system!

When fi lling the system for the fi rst time, strictly adhere to the sequence of steps below:

• Clean the fi ller screws and caps of the transport and storage containers of the hydraulic oil.

• Check the quality of the hydraulic oil; for instructions, see chapter „Maintenance“.

• Filter the hydraulic oil in a mobile fi lter unit with fi lter size 3 μm (118.11 μinch).

• Ensure that the main switch of the machine is in the OFF position and secured against inadvertent switching on.

• If necessary, remove the protective guards or covers.

• Clean the area around the fi ller and breather fi lter.

• Unscrew the plug of the fi lling and breather fi lter (ensure that the fi lter screen remains in its position).



Initial fi lling of the oil tank with „Clamping side open“

• Fill the hydraulic tank through a mobile fi lter unit with fi lter size 3 μm (118.11 μinch) until the fl oat in the oil sight glass reaches the max. mark. The oil sight glass is located at the clamping side of the machine.

In this situation, do not fi ll in oil to the max. mark.

CAUTIONBefore switching on the machine, allow the hydraulic oil to settle for 1 hour so that all air bubbles can escape!

Sw

itchi

ng le

vel

50 m

m (1

.97"

)

HM_1014.PMP

EP6GB0EAEP6DE0EA



4.10.2 Commissioning of hydraulic pump• Activating the pump idling program for the pump system 1 and pump system 2 (optional

equipment)

• Starting machine

• If there is air in the pump system, for example after the replacement of the pump or an oil change, this air is removed from the system by running this program.

• The pump program should be activated for approx. 20 minutes. Subsequently deactivate the program.

• During machine operation, the oil level should always be between the max. and min. mark.

If the maximum fi lling level is exceeded, hydraulic oil escapes through the breather fi lter! In this case, clean the intake pipe and the fi lter housing and replace the fi lter cartridge!

• Reinstall the fi lling and breather fi lter on the pipe piece.

• If necessary, mount the protective guard or cover.

UNILOG B6



4.10.3 Bleeding systemAfter the hydraulic tank has been fi lled, you must bleed the hydraulic system.

• Connect the machine to the electric power supply; see section „Electrical system“.

• Connect the machine to the cooling water system, if necessary; see section „Water system“.

• Start the hydraulic drive with the „Hydraulic Start“ button.

• Press the „Setup“ button.

• Open all safety gates once and close them again.

• Move the clamping plate, the nozzle and the screw several times back and fore across the entire stroke length.

The system is properly bled, if no oil foam is visible in the hydraulic tank, all movements are performed smoothly and there are no unusual machine noises.

After bleeding, check the oil level and add oil, if necessary. Only add oil of the same grade.

Any leakage occurring within the fi rst few hours of operation can normally be eliminated by retightening the fi ttings.

4.10.4 Core puller (optional) See chapter „Design and function“.

The hydraulic core pullers must be connected and commissioned by a specialist hydraulic technician! Always strictly adhere to the safety instructions in chapter „Safety“!

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EP6GB0FAEP6DE0FA0510WT Chapter 4.11 - 1

4.11 Water system

CAUTIONWhen installing the water lines, observe the corrosion properties of metal components when exposed to water as laid down in DIN 50930!

4.11.1 Water qualityIf the quality of the water at your site deviates from the guide values below, please contact our technical customers service or one of our agents. For addresses, see chapter „Customer service“.

• pH: 6.5 - 9

• Water hardness: < 1.8 mmol / l (681 ppm / gal)

• Suspended particles: < 0.03 ‰ (30 ppm)

• Filter mesh size: < 100 μm (0.004")

As regards suspended particles and water hardness, please note that the concentration of suspended particles must be lower the harder the cooling water. If the concentration of suspended particles is above 0.03 ‰ (30 ppm), install a water fi lter with a fi lter mesh size of < 100 μm (0.004") in front of the water system.

We recommend adding a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel).

Recommended anti-freeze agent: ethylene glycol type 420 (60 % water, 40 % ethylene glycol). This additive is suitable for temperatures down to -30 °C (-22 °F) and also serves as a corrosion inhibitor.

Max. water fl ow rate Aluminium / aluminium alloy m/s 1,8 Brass/bronze m/s 2,4 Steel m/s 6 Rubber/plastic m/s 5

Cooling water quality - guide values Cooling water temperature °C < 30 Min. pH 7 Max. pH 8,5 Min. total hardness mol/ccm 0,5 Max. total hardness mol/ccm 10 Min. carbon hardness mol/ccm 1 Max. carbon hardness mol/ccm 2 Chloride ions (max.) mg/l 200 Sulphate ions (max.) mg/l 325 Nitrates and nitrites (max.) mg/l 50 Ammonia (max.) mg/l 0,5 Iron (max.) mg/l 0,2 Manganese (max.) mg/l 0,1

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4.11.2 Cooling water connection

If the cooling water system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

The cooling water devices of the machine can also be connected to a closed cooling circuit. Use clean and lime-free water, if possible. The required nominal diameters of the hoses are specifi ed in chapter „Technical data“. The diameters of the inlet and outlet lines must not be smaller that those of the connections on the machine.

The machine is equipped with a four-circuit cooling water battery of type WITTMANN fl ow controller series 101. One of the four cooling water circuits is assigned:

• Cooling of feed zone

Depending on the requirements of the customer, the machien can be factory-equipped with various types of cooling water batteries. The following fi gures are therefore examples only.

To prevent galvanic and/or biological corrosion as well as organic and inorganic deposits, observe the following:

• Cooling water quality requirements

• Instructions by BATTENFELD for the operation of the motor fl ange and feed zone cooling (see chapter 13)

• Instructions of the mould manufacturer

• Use of material for fi ttings, hose lines and pipes that takes into account the electrochemical series

The feed and outlet lines must be installed in such a way that they cannot become damaged. Ensure that the hoses do not present a tripping hazard.

The cooling water inlet and outlet lines must be installed with G1" to the machine. The connections of the cooling water battery must consists of G 3/4" lines.

If rigid pipes are used, you must install hose inserts for the inlet and outlet. The cooling water battery is equipped with a 3/4" hose nipple. The inlet at the cooling water battery must always be connected at the lower hose connection, while the return line is connected at the top.



1 Cooling water outlet, 3/4" connection

2 Cooling water inlet,

3/4" connection

The inlets and outlets of the mould are connected at the base of the cooling water battery. The feed connections are located at the front, and the return connections at the back.

In machines with controlled cooling circuits (optional), the return connections are located at the front and the feed connections at the back!

The cooling water circuit can be controlled with suitable equipment installed in the feed or the return line. This means that the water circuit can be operated under pressure or without pressure.

In highly restricted cooling water circuits, it is often advisable to control the return fl ow to ensure that water fl ows through all cooling water channels.

The cooling water battery can be connected to a heater, if there is a need to heat up the moulds.

The transparent pipe sections with scales and fl oats allow the operator to monitor the fl ow rate in each cooling water circuit. These pipe sections are easy to clean by unscrewing the screw cap at the top and cleaning the pipe with the brush. Alternatively, the pipe can be removed by pulling it out. The greater the fl ow rate, the higher the fl oat in the pipe. The position of the fl oat thus indicates the fl ow rate. (For details, see the fl ow diagram in the operating manual of the manufacturer.)

1

2

Wittmann 101 / 301 fl ow controllerFlow rate range per cycle 0 - 10 l/min (30 l/min)Temperature °C [°F] 40 [104] 60 [140] 80 [176]Pressure bar [psi] 8 [116] 6 [87] 4 [58]

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Blow-off valve:

The blow-off valve is installed in the lower distribution channel of the cooling water battery.

This valve is used to blow out the water from the cooling channels prior to a mould change. This is done to prevent corrosion (caused by escaping water) in the cooling channels and on the mould surfaces in the mould store.

A compressed air hose is connected to the G 1/4" fi tting. By opening the stop valve, the water in the hoses and the mould is blown out. This ensures clean and dry mould change.

Procedure: • Close the water inlet line.

• Open the compressed air stop valve.

• By opening the regulating valves of the individual circuits (feed and return) and closing the other circuits, you can now blow out one circuit after the other, until all water is removed from the sight tube.

4.11.3 Oil cooling system (optional)The hydraulic oil is cooled in a heat exchanger. In the oil cooler, the cooling water is fed through cooling coils installed in the hydraulic oil reservoir.

The cooling water fl ow rate is regulated by a pilot-controlled solenoid valve. It controls the cooling water fl ow based on the hydraulic oil temperature, ensuring that the oil is kept at a constant temperature.

A temperature sensor in the hydraulic tank measures and monitors the oil temperature and transmits the measured values to the IMM control unit. Depending on these signals, the solenoid valve is opened or closed.



The water lines for the cooling of the hydraulic system must be installed by a specialist fi tter. All fi ttings, lengths and cross-sections must meet the requirements!

• The cooling water hoses must be installed in such a way that proper and constant water infeed and return fl ow is ensured. Ensure that lines cannot become kinked or squeezed, restricting the cooling water fl ow.

• The hoses must be suitable for the specifi ed system pressure and ambient temperatures.

For optimum effi ciency of the machine, the oil temperature should be between 45 °C and 50 °C (113 °F and 122 °F). The inlet water temperature must not exceed 30 °C (86°F).

Cooling water consumption:

4.11.4 Heating/cooling unitHeating/cooling devices (optional) are used to adjust the temperature of the mould, the screw barrel, and/or the screw.

Before operating the machine, read the safety instructions and operating manual for the injection moulding machine and the heating/cooling device!

Heating/cooling devices must be installed and connected by a qualifi ed electrician (in accordance with DIN VDE 0105 and IEC 364)!

For the installation, connection and commissioning of the heating/cooling device, follow the instructions in the separate operating manual and refer to the wiring diagram in chapter „Spare parts / plans“.

The relevant interfaces are located on the side of the switch cabinet.

Water side max. 10 bar 145 psiWater 2 m/s 1,8 yd/s

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EP6GB0GAEP6DE0GA0510WT Chapter 4.12 - 1

4.12 Pneumatic system

The compressed air lines for the pneumatic system must be installed and connected by a specialist technician. All fi ttings, lengths and cross-sections must meet the requirements!All work on the pneumatic system must be carried out by a specialist pneumatic technician!If the pneumatic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

4.12.1 Compressed air connectionCompressed air is required for the movement of the injection unit and for the pneumatic shut-off nozzle (accessory equipment).

The compressed air supply line must be equipped with a shut-off valve. Before carrying out out any maintenance work on the machine, close the supply lines.

The compressed air must be supplied at a pressure of minimum 6 bar. Please refer to the general layout plans enclosed with the machine.

EP6GB0GAEP6DE0GA



4.12.2 UNIFEED material feed unit

UNIFEED material feed unit (optional) replaces the bulk material hopper, and does away with production stops for the fi lling of the hopper.

The UNIFEED unit is the preferred feed option for the following materials: PE-HD, PE-LD, PS, PA, PA + GF, PP, ABS, POM, PPO.

In general, the material feed unit is suitable for the feeding of regenerated material in conjunction with new granule material. The grain size must not exceed 3 to 4 mm (0.12 to 0.16").

If the material feed unit is installed above head level, use safe climbing aids and work platforms and comply with all relevant statutory safety regulations and instructions!

• Position the climbing aid in front of the injection moulding machine.

• Place the material feed unit on the hopper support and secure it with 2 screws (enclosed with unit).

• Align the suction lance to the retaining bores and the material container.

• Mount the air valve and the proximity switch and connect them according to the wiring diagram.

• Position the proximity switch directly at the acrylic glass and adjust it with the adjusting screw so that the LED is on when the container is full and is off when the container is empty.

• Connect the compressed air hose (DN 10 mm / 0.4") to the connecting piece and secure it with a hose clamp.

• The compressed air hose must be installed in such a way that the compressed air fl ow is not obstructed. Avoid kinking and squeezing of the hose.

• Ensure that the hose is long enough to cater for the travelling movements of the injection unit.

• The hose must be suitable for a system pressure of max. 7 bar / 101 psi and the expected ambient temperatures.


EM6GB0HAEM6DE0HA68WT Chapter 4.13 - 29

4.13 Electrical equipmentThe machine may only be connected to a power supply which corresponds in phase, voltage andfrequency to the data given on the electrical specification plate.

Electrical installation may only be carried out by a qualified electrician (qualified to DINVDE 0105 or IEC 364 or equivalent)!The electrical supply lines must be designed according to the specifications on the nameplate!The currently valid local regulations on earthing and overload protection (overload, wrongpolarity protection) in TN-, IT- or TT supplies must be observed without fail by theproprietor of the machine!The protection for the phase conductors and the neutral conductor (IT-supply) must bearranged to comply with the data on the electrical specification plate!Connection as "Classical zerorising" (PEN-conductor) must not be used. PE-conductor andN-conductor (if used) must always be connected separately!

The connecting terminals for drive and heating are located in the switch cabinet. The phaseconductors are connected directly to the main switch.

It is possible to connect the machine with two separate supplies for the motor and heatingcircuits. If the machine is equipped with two separate power connections, they must not beconnected to a joint supply line. Hence there are four connection schemes:

1 - Lead without neutral

2 - Lead with neutral

1T31T2

1T1

4 (L1, L2, L3, PE)

5 (L1, L2, L3, N, PE)

1T11T2 N

1T3

EM6GB0HAEM6DE0HA



3 - Separate leads for drive and heating without neutral

4 - Separate leads for drive and heating with neutral

Checking the direction of three phase motor of the mould height adjustment

Before switching on the machine it must be ensured that:

• The switch cabinet must be closed.

• The guarding and safety gates must have been properly fitted and closed.

ATTENTIONIf the direction of rotation is wrong, the mould height cannot be adjusted correctly and/orthe clamping force cannto be controlled correctly!

• Connect the supplies; see paragraph "Electrical equipment".

The hydraulic motor’s direction of the three phase motor may only be tested by a qualifiedelectrician (qualified to DIN VDE 0105 or IEC 364 or equivalent)!

• Open the electrical cabinet.

• Connect a phase sensor to lines 1L1, 1L2 and 1L3 on the main switch.

4 (L1, L2, L3, PE)

4 (L1, L2, L3, PE)

1T11T2 2T3

2T22T1

1T3

1T11T2

N2T3

2T22T1

1T3

4 (L1, L2, L3, PE)

5 (L1, L2, L3, N, PE)


EM6GB0HAEM6DE0HA68WT Chapter 4.13 - 31

• Switch on the supply voltage (low voltage distribution).

• The phase sensor should now indicate a right-hand (clockwise) field.

• Switch off the supply voltage (low voltage distribution) if the direction of rotation is notcorrect and exchange two phases of the power connections 1L1, 1L2, and 1L3 of themains lead in the switch cabinet.

• Close the switch cabinet.

Only peripherical devices which correspond to the VDO requirements and the EMCregulations (electromagnetic compatibility) of electrical operating materials may beoperated on the machine.Cabling which was additionally fitted to the machine by the proprietor must correspond tothe EMC regulations (electromagnetic compatibility).

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Mould mounting

EM6GB0IAEM6DE0IA68WT Chapter 5 - 1

5 Mould mounting

5.1 PreparationIf the machine has a robot interface and the machine is to be run without the robot, then the lattershould be switched off and the supplied dummy plug must be inserted. Operation of the machinewithout this linking out is not possible. The installation of the links is detailed under "Interfaces".

It is a good idea to check the following before mounting a mould, to avoid unnecessary work:

• Mould height and dimensions must suit the machine.

• The sprue bush or hot runner radius must correspond to the machine nozzle radius.

• The centring flange must correspond to the centre bore in the nozzle and clamping platen.

• The length of the ejector bar and the ejector stroke must be compared with the machinespecification (see chapter "Technical Data").

• Check that the water fittings are the right size.

• The mould should have been checked for binding, seizing, missing or loose parts andbadly adjusted slide valves.

• Water and air connections should be made to check for leakage.

5.2 Mould mountingThe mould may only be mounted by an authorised skilled technician!

1 Switch on main switch.

2 Press and release the emergency stop buttons on the machine and robot, if present; the"Test emergency stop" error message will disappear

3 Turn on water supply to oil cooler

4 Check the safety device as described in the "Checking safety devices" paragraph.

5 Open and close all safety gates once (to test the safety gate monitoring).

Press the "Open safety gate" and "Close safety gate" keys in case of a power-operated safety gate (option).

6 The hydraulic drive and at the same time the oil pre-heating are switched on with the "DriveOn" key

EM6GB0IAEM6DE0IA

68WTChapter 5 - 2

Mould mounting

7 After the control boots up the "Start page" screen page will appear.

8 Press the "Alarms" menu key; a list of the active error messages will be displayed,including the "Oil heating - Tolerance" error message.

This error message disappears automatically as soon as the hydraulic oil comes up tooperating temperature.

See also the "Interrupt list" chapter in the " UNILOG B6 User manual".

9 An activation of the key symbol opens the window for "System password".

10 For the log on to the control refer to chapter A 7 in the control unit’s manual.

If further error messages are displayed, see the "UNILOG B6 User manual", "Interrupt list"chapter to find out how to clear them. Once all the errors are cleared and the drive is started,mould mounting can be continued.

11 Adjust the mould mounting height

11.1 Press the "Manual operation" key.

11.2 Press the "Injection unit back" key and move the injection unit (the nozzle) back.

Mould mounting


11.3 Press the "Mould close" key and close the clamping platen, and check that the clampingplaten is in the "Mould closed" position.

11.4 Check the position of the toggle. The toggle must have reached the locked out position.

11.5 Press the "Decrease mould height" key once (switches function on); yellow LED mustlight.

Press "Decrease mould height" key again (performs function).

11.6 Determine mould height (from drawing or by measurement).

11.7 Press the "Increase mould height" key and move the platen back until the mould height isreached.

12 Clamping the mould on the nozzle platen

12.1 Press the "Mould open" key and open the clamping platen.

12.2 Press the "Setting mode" key; this avoids damaging the mould on initial opening.

The mould may only be mounted by an authorised skilled technician!The lifting equipment must at least correspond to the weight of the mould. For detailsplease refer to the manufacturer of the mould!

12.3 The mould halves must be prevented from sliding apart.

12.4 The mould must hang horizontally from the lifting equipment.

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68WTChapter 5 - 4

Mould mounting

= == =

Danger of death! It must be ensured that no persons stand or linger under the suspendedload!

12.5 Bring the mould into the open clamping unit.

12.6 Locate the mould in the nozzle platen’s centring hole. (with the exception of circular discs- the rotary unit should be centered here!)

12.7 Position the mould square to the machine’s lateral axis.

ATTENTIONThe number of mould clamps must be adapted to the mould weight and the opening forceof the machine!

12.8 Clamp the mould to the nozzle platen with mould clamps; it is essential to use bolts of thecorrect length; at least 1.5 D (= diameters of thread) must screw into the machine platen.

The mould clamps (mounting elements for the mould; not supplied as standard with themachine) must be the same height as the thickness of the mould mounting platen, asotherwise 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.

Mould mounting


12.9 Press the "Mould Close" key and close the clamping platen.

13 Clamping the mould to the clamping platen

13.1 Clamp the mould to the clamping platen with mould clamps; make sure the screws are thecorrect length; see step 11.8.

The lifting equipment should not be removed until the mould is bolted securely to bothplatens and this has been verified by an authorised technician!

13.2 Remove lifting gear from mould, mount the safety strap holding the two mould halvestogether, connect the ejector coupling (mould / hydraulic ejector cylinder).

13.3 Press the "Mould open" key and open the clamping platen.

14 Set clamping force

As the double toggle system can only achieve its full clamping force with the toggles locked out,the mould height and thus the clamp force must be adjusted after a mould change.

To increase the clamping force (i.e. to reduce the mould height) the "Decrease mould height" keymust be pressed. The clamp force is reduced by pressing the "Increase mould height" key.

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68WTChapter 5 - 6

Mould mounting

14.1 Press the "Manual operation" key.

14.2 Press the "Clamping unit" menu key.

The "Clamping unit" page appears.

14.3 If the input field "Clamping force" is pressed, the "Numpad" appears. Here, the wishedclamping force can be entered in "kN" (shtn) (see also User manual A5).

14.4 Press "Mould open" key and crack the clamping platen open.

14.5 Press the "Decrease mould height" key: a second time if necessary (switch on / performfunction). This closes the mould and an increase in clamp force is achieved.

14.6 Press the "Mould Close" key and close the clamping platen.

Check whether the desired clamping force has been reached; the current clamping forcewill be displayed in green next to the "Clamping force" set value field.

If the desired clamping force is still not reached, the procedure must be repeated from step14.4 onwards.

14.7 This process is now repeated until the correct clamp force is achieved.

The same procedure (steps 14.7 to 14.7) also applies for a reduction in clamping force.

Press the "Mould open" key - press the "Increase mould height key".

In this way the mould is opened and the clamp force reduced.

Mould mounting


15 Log off from the control

ATTENTIONTo prevent set value entries by unauthorised persons, the user must log off after finishingsetting!

15.1 An activation of the key symbol opens the window for "System password".

If you want to interrupt or finish your work at the control unit, you will have to logout first.This procedure prevents unauthorised input at the control unit.

15.2 Select the "Logout" key.

If the logout is successful, the window is automatically closed. As an acknowledgement,user level 90 is displayed in the "User level symbol".

16 Connect the cavity pressure measuring (option) and temperature sensors.

ATTENTIONThe cables must be laid and installed as not to be damaged by the mould or the machine.

17 Connect the mould heating and cooling.

ATTENTIONPlease note the correct passage direction since the cooling may otherwise be subject tonegative influences.The lines and cables must be laid and installed as not to be damaged by the mould or themachine.

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68WTChapter 5 - 8

Mould mounting

5.3 Quick-action mould mounting systemUse the "Mouldfix" quick-action mould mounting system (option) to enable quick installation anddismantling while the injection mould will automatically be levelled.

It may either be levelled horizontally or vertically depending on whether the injection moulds areto be installed laterally using a rolling truck or from above using a crane.

Mould mounting

1 Switch on the machine as described in "Mould mouting", steps 1 to 10 (paragraph 5.2).

2 Adjust the mould mounting height as described in Step 11 (par. 5.2) "Adjusting the mouldmounting height".

3 Press the "Setting mode" key.

4 Move clamping platen fully back.

5 Move injection unit fully back.

Only then may the wedge clamping elements of the "Mouldfix" be moved out (released).

6 Switch on key-operated "Mouldfix" switch (Position 1).

7 Move out (release) the wedge clamping elements of the "Mouldfix" for the nozzleand the clamping platen until reaching the "Wedge clamping elements released"limit switches. If the limit switches have not been reached the movements of theclamping platen will be disabled.

8 The mould parts must be prevented from sliding apart.

9 Move the mould with the adapter platen of the nozzle unit into the nozzle platen’s"Mouldfix" until reaching the limit stop.

0 1

Mould mounting


10 Clamp the nozzle side part of the mould to the nozzle platen by activating the wedgeclamping elements of the "Mouldfix" for the nozzle platen until reaching the "Wedgeclamping elements released" limit switches. If the limit switches have not been reachedthe movements of the clamping platen will be disabled.

11 Move the clamping platen slowly forward until the mould is closed and the clamping unit’sentire adapter platen fits to the clamping platen.

12 Clamp the clamping unit’s part of the injection mould to the clamping platen by activatingthe wedge clamping elements of the "Mouldfix" for the clamping platen until reaching the"Wedge clamping elements released" limit switches. If the limit switches have not beenreached the closing movement will be disabled.

13 Remove the safety devices for the preventing the injection mould from collapsing.

14 Switch off key-operated "Mouldfix" switch (Position 0).

Remove the key to protect the mould and prevent unauthorised reconnection.

To dismantle the injection mould proceed in reversed order.

The self-locking function of the wedge clamping elements prevents any part of the injection mould- even if the hydraulic pressure drops to zero - from disengaging automatically from the mouldmounting platen.

0 1

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68WTChapter 5 - 10

Mould mounting

5.4 Magnetic quick-action mould mounting systemThe magnetic quick-action mould mounting system (option) is another option for quicklymounting or dismantling the mould.

Use eccentric rings to centre the injection mould in the clamping and nozzle platen. At the sametime the centering rings are to support the mould if the magnetic retention force is exceededwhen opening the mould.

Before mounting the mould the enclosed separate operating manual must be read. It containsinformation on safety equipment, requirements on the mould, mould mounting, commissioning,set value entries and maintenance.

Mould mounting

1 Prepare the mould according to the operating instructions for the magnetic quick-actionmould mounting system.

2 Switch on the machine as described in "Mould mouting", steps 1 to 10 (paragraph 5.2).

3 Adjust the mould mounting height as described in Step 11 (par. 5.2) "Adjusting the mouldmounting height".

4 Press the "Setting mode" key.

5 Move clamping platen fully back.

6 Move injection unit fully back.

7 Check the contact surfaces of the magnetic contact surfaces and the mould for dents andeliminate them, clean them thoroughly and spray them with corrosion inhibitor.

8 Check whether magnetic modules have been demagnetised.

Mould mounting


9 Centre mould on the nozzle platen as described in steps 12.2 to 12.6 (paragraph 5,2Mould mounting).

Magnetic field hazard. The magnetic field will almost close completely in the base plate ofthe mould (in a depth of 12 mm / 0.47 inch). However, when in immediate proximity, itmay influence sensitive devices such as cardiac pacemakers, hearing aids, disks, etc.!

ATTENTIONThe power of the magnetic modules amounts to up to 16 kg / cm2 (5,58 lb / sq.in.). Duringmagnetising an object between the mould and the magnetic module will be uncontrollablyclamped and damaged!

10 Ensure that thereare no magnetisable objects (e.g. spanners) within the clamping unitarea.

11 Magnetise the nozzle unit’s magnet mounting plate.

12 Check the clamping procedure; the respective pilot lamp must light up on the control panelor the manual operation unit.

13 Remove lifting gear from mould.

14 Press the "Mould Close" key and close the clamping platen.

15 Magnetise the clamping unit‘s magnet mounting platen.

16 Check the clamping procedure; the green pilot lamp must light up on the control panel orthe manual operation unit.

17 Remove the safety strap holding the two mould halves together.

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68WTChapter 5 - 12

Mould mounting

5.5 InterfacesThe 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 OperatingManuals.

Before operating the machine with peripheral equipment, it is essential that the safetyregulations 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 isoperated 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 turnclockwise and program selection switches set to the required position.

The start impulse for automatic operation of a peripheral device is given by starting an automaticcycle of the machine.

Automatic operation is ended by operating an emergency stop button or by switching off orchanging the automatic cycle of the machine.

5.6 Checking the safety devicesThe safety devices can only fulfil their purpose if their faultless operation can be guaranteed.Therefore it is necessary to check the following for effective function before operation:

The function test for the safety device may only be carried out by a trained and skilledtechnician!

• Electrical closing interlock: Proper function and securely fixed limit switches.

• Hydraulic interlock: Proper function and securely fixed limit switch.

• Mechanical scotch (option): Proper function and free movement of scotch (flag) on theclamping platen and the correct position (teeth) of the scotch bar as well as the securefitting of the limit switch.

Mould mounting


If a fault appears on the machine which causes the mechanical scotch to come intooperation, Battenfeld Customer Service or the responsible agent must be contacted.

• Purge guard: Function, free movement and securely fixed limit switche

• Purge guard, safety gate and guarding: Security of all fixing bolts and undamaged conditionand proper function

5.7 Test run and interlock test

Operating and other personnel may only stand in front of the machine on the operator’sside 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 befollowed without fail!

• After electrical installation safety devices are to be tested

• Check hydraulic lines and components for leaks

• Check all visible fittings for security

• Close safety gates and check for proper fitting

• Clear inside of the machine of all foreign bodies (forgotten mould)

• Set peripheral equipment to the starting position, i.e. the position in which no damage to itor to machine components is possible.

• Turn on water supply to oil cooler

• Check function of safety devices.

ATTENTIONIt 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.

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68WTChapter 5 - 14

Mould mounting

• Open and close the clamping unit’s safety gate (to check the safety gatemonitoring).

Press the "Open safety gate" and "Close safety gate" keys in case of apower-operated safety gate (option) and open and close the safety gatesentirely.

• 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 mouldmounting, open it with the "Mould open" key.

The movements of the other units (ejector, screw and nozzle) can now be checked andtheir functions tested.

Design and function

EP6GB0JAEP6DE0JA1209WT Chapter 6 - 1

6 Design and function

6.1 Clamping unit

6.2 Injection unit

6.3 Hydraulic system (optional)

6.4 Pneumatic system (optional)

6.5 Airmould (optional)

6.6 Electrics

6.7 Control system

6.1 6.7 6.26.66.3

EP6GB0JAEP6DE0JA

1209WTChapter 6 - 2

Design and function

Design and function

EP6GB0KAEP6DE0KA0510WT Chapter 6.1 - 1

6.1 Clamping unit

6.1.1 Technical descriptionThe clamping unit consists essentially of the clamping plate (1) with mounted hydraulic or servoelectric ejector (2), the nozzle plate (3), the front plate (4), the motor for the clamping movement (5) and the beams (6), the toggle (7) with the low-maintenance guide bushings (8) and the height adjusting unit (9).

The entire clamping unit is designed as a self-supporting assembly that is permanently fi xed to the machine frame through screws in the nozzle plate.

To ensure unhindered expansion of the beams, the front page is not fi xed with screws to the machine frame.

The moving clamping plate is guided by the clamping plate support on the machine frame. A rotary encoder in the motor of the clamping unit records the travelling movement of the clamping plate and transfers the data to the injection moulding machine control system.

The clamping force is applied through a 5-point toggle system, which is driven by a directly connected spindle motor. This ensure high travelling speeds at minimum energy consumption.

The clamping force is monitored by a proximity switch (8 + 2 - contact-free limit switch).

2 345

6

789 1

EP6GB0KAEP6DE0KA


Design and function

The low-maintenance guide system of the clamping plate located above the beams and the support of the clamping plate ensure that the plate is kept in a perfect horizontal position during the entire stroke.

The mould height can be adjusted by means of the hydraulically operated height adjusting unit, whose adjusting speed can be programmed depending on the operating status. This means that the setup procedure can be completed in very short times. The minimum and maximum mould heights are monitored by two limit switcheslocated on the machine operating side.

The hydraulic ejector is mounted in the clamping plate and is designed as a double-acting hydraulic cylinder. The stroke transducer records the travelling movement of the ejector and transfers the data to the machine control system.

6.1.2 Lubrication of toggle systemThe automatic central lubrication system for adhesive oil supplies the connected lube points at regular intervals with an exactly metered amount of adhesive oil.

The lubrication intervals depend on the cycles of the machine and can be changed through the control system. Factory-set lubrication intervals:

EcoPower 55-300 lubricant quantityRotary table diameter 55 110 180 240 300Lube points 12 12 18 18 18Number of lubrication processes 2 2 2 2 2Amount of lubricant (ccm / 2 lubrication cycles) 0,92 0,92 1,8 1,8 1,8Lubrication cycle duration (sec.) 10 10 10 10 10Lubrication intervals 13000 10000 10000 7000 6000Amount of lubricant (l) / 1 million cycles 0,14 0,18 0,36 0,51 0,6

Design and function


The central lubrication system for adhesive oil consists mainly of a pump unit with a gear pump, a container, the piston distributors and the lubricant lines.

The pump unit is started automatically as soon as the machine is switched on by the main switch. After 3 to 15 seconds, the pump has established the operating pressure. After another 15 seconds, it is switched off and the system is depressurised. At this point, the lubrication process is completed.

After the preset number of cycles, which correspond to the working cycles of the machine, the control system switches on the pump again to complete the next lubrication process.

The piston distributors meter and distribute the oil fed by the pump through the main line. Each lube point is assigned its own piston distributor.

• The piston distribution features a distribution piston whose cylinder is fi lled in front of the piston with the oil indented for the respective lube point. The oil volume is metered by the metering nipple. This nipple is screwed into the piston distributor and limits the stroke of the distribution piston.

• When the pump is started, the oil pushes the distribution piston in the piston distributor forward against the metering nipple, and the oil in front of the piston is pressed with the pump pressure to the lube point.

• As soon as the pump is switched off, the oil pressure in the main line drops and the distribution piston returns to its initial position. At this point, the oil for the next lubrication interval is fed into the distribution piston cylinder.

The amount of oil supplied to the lube points can be adjusted by changing the lubrication interval at the pump unit.

The oil level in the container of the pump unit must be checked daily. It must not drop below the „min“ mark (for oil quality specifi cations, see chapter „Maintenance“).

EP6GB0KAEP6DE0KA


Design and function

6.1.3 Central lubrication pumpDesign:

1 DC motor

2 Screw drive

3 Eccentric shaft

4 Piston

5 Piston outlet screw

6 Delivery piston

7 Grease screen

8 Agitator blade

9 Grease container

10 Secondary piston

11 Conical helical spring

12 Tracer pin

13 Overfi ll safety device

14 Pressure-relief valve

3

9

8

10

7

11

2

11

112

2 3

4

5

6

32131

6

5

32

7810

9

11

12

4

Anschluss Signal-geber / Steuer-gerät

Connection signalling device/control

unit

Central lubrication pump without control unit

14

Design and function


Functional descriptionThe central lubrication pump is an electric lubricant pump.

The pump is equipped with a fi lling level sensor as standard. To ensure that no air is taken in by the system, the pump is automatically switched off when the minimum grease level is reached.

The lubrication intervals depend on the working cycles of the machine. Factory-set lubrication intervals:

EcoPower 55-300 lubricant quantityRotary table diameter 55 HY 110 HY 180 HY 55 SE 110 SE 180 SELube points 3 3 4 6 6 7Number of lubrication processes 2 2 2 2 2 2Amount of lubricant (ccm / 2 lubrication cycles) 0,29 0,29 0,35 0,44 0,44 0,5Lubrication cycle duration (sec.) 60 60 100 60 100 100Lubrication intervals 5000 2000 1000 5000 2000 1000Amount of lubricant (l) / 1 million cycles 0,12 0,29 0,7 0,18 0,44 1

EP6GB0KAEP6DE0KA


Design and function

6.1.4 Turn-out deviceThe hydraulically powered motor of the turn-out device (1) is mounted on the clamping plate in the place of the hydraulic ejector. The hydraulic ejector is supplied as a separate assembly.

All work on the hydraulic system must be carried out by a specialist hydraulic technician! Always strictly adhere to the safety instructions in chapter „Safety“!If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

• Turn the „Pressure relief“ key switch. In machines with hydraulic core puller, ejector, etc. with quick-release couplings, the hydraulic system must be completely depressurised by means of the key switch before the hose lines are disconnected.

• Shut down the machine as described in chapter “Operation”, section “Shutting down machine”.

• Disconnect the mechanical connection between the mould and the turn-out device.

• Thoroughly clean the area around the connecting points of the hydraulic hose connections and the fi ttings at the rear side of the machine.

• Disconnect the hydraulic lines of the turn-out device. Collect residual oil in a suitable container.

• Seal the hydraulic connections of the turn-out device with suitable plugs.

• Remove the screws and the turn-out device.

• Mount the hydraulic ejector by completing the above steps in reverse order.

1

Design and function


6.1.5 Mechanical closing guardThe mechanical closing guard (optional) prevents the clamping plate from closing when the safety gate is open.

The mechanical closing guard consists mainly of a stop bar equipped with saw-type teeth, the stop, the stroke solenoid or pneumatic stroke cylinder and a position monitoring unit.

CAUTIONThe mechanical closing guard is a safety device designed to prevent accidents. It can only work properly, if all its components are in proper working order and the parts can move freely. Please note that the stop surface against which the tooth of the stop bar is pressed when in locking position is exposed to wear. Timely replacement of the stop helps prevent malfunctions of the mechanical closing guard!

The stop bar is mounted at the operating side of the clamping plate and slides through the stop tube, which is attached to the front plate.

The stop tube is equipped with a stroke solenoid of pneumatic stroke cylinder with stop. The stop touches the stop bar as long as the stroke solenoid or the pneumatic stroke cylinder is not actuated.

When the safety doors are closed, the stroke solenoid of the pneumatic stroke cylinder lift the swivelling stop.

As soon as one of the safety doors is opened, the power supply is interrupted and the stroke solenoid of the pneumatic stroke cylinder returns to its neutral position. The stop is lowered and positioned in front of a tooth of the stop bar, thus preventing the clamping plate from clamping.

EP6GB0KAEP6DE0KA


Design and function

Design and function

EP6GB0LAEP6DE0LA0510WT Chapter 6.2 - 1

6.2 Injection unit

6.2.1 Technical description

1 Nozzle pressure cylinder

2 Guide of hopper base

3 Guide rails of injection unit

4 Material feed block

5 Screw barrel, shaft and mount

6 Injection spindle

7 Linear guides of injection drive

8 Screw lock

1

2

4

3

5

7

68

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Design and function

The injection unit consists of the screw barrel in which the material is melted and from which it is injected into the mould. It further includes a material hopper into which the raw material to be injection-moulded is fi lled, normally in the form of granules.

The feed zone is water-cooled to prevent the melted material from becoming stuck in the material feed zone.

The screw barrel is equipped with heating bands for plasticising. The screw transports the raw material from the hopper to the head of the screw barrel. In the process, the material is plasticised and homogenisd.

As the plasticised material collects in front of the screw tip, the screw is pushed backwards, until the set plasticisation path is reached and screw rotation is stopped.

After the mould has been closed and the clamping force is established, the actual injection process is started. At this point, the entire screw is pushed forward like a piston and the plasticised material is injected under high pressure through the nozzle into the mould.

The nozzle consists of a nozzle head and a nozzle body and connects the screw barrel with the mould.

The screw barrel is secured by a yoke. The injection and plasticisation is carried out by means of water-cooled servo motors and a toothed belt drive. During injection, the force is transferred through a ball-type linear drive.

The injection unit is mounted on a linear guide. It is moved forward and back by means of a hydraulic or servo-electric nozzle pressure cylinder.

Design and function


6.2.2 Centring of nozzle

Risk of injury from burns when touching the nozzle or its heating elements. Wear suitable protective clothing!

For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations!

Never use machine components as climbing aids! When working at height, wear fall arrest gear!

Use only tools and equipment that cannot cause damage to the components described below!

Risk of injury and damage to components! Use only components (nozzle, screw, screw barrel, fi xing screws) that have been supplied by Battenfeld or meet the Battenfeld specifi cations.

For the tightening torques of the screws, see chapter “Technical data”, section 2.13 and the spare parts list.

1 Heat the cylinder.

2 Remove the paneling from the injection unit.

EP6GB0LAEP6DE0LA


Design and function

1

2

3

2

4

3 Detach the screw (4) from the screw coupling. Loosen the 4 screws (1) of the screw coupling (2) and remove the 2 feather keys (3).

4 Press the „Setup mode“ button.

Design and function


5 Actuate the button for injection piston movement until the nozzle tip (5) is in line with the nozzle plate (6).

6 Using a caliper gauge, determine the horizontal eccentricity of the nozzle by repeatedly measuring the distance from the nozzle bore to the mould centring bore. The offset must not exceed 0.2 mm (0.008").

5

6

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Design and function

7 To move the nozzle in horizontal direction to the centre, loosen the top screws (7) on the adjusting block (8). Loosen the lock nut (9) and the adjusting screws (10) to the left and right on the adjusting block (8). Depending on the direction in which the nozzle is to be moved, turn the lateral screws in or out.

8 After the nozzle is properly aligned in horizontal direction, tighten the lock nut (9) and the adjusting screws (10) and the top screws at the adjusting block (7).

8

108 97

Design and function


9 Using a caliper gauge, determine the vertical position of the nozzle by repeatedly measuring the distance from the nozzle bore to the mould centring bore. The offset must not exceed 0.2 mm (0.008").

10 To align the nozzle horizontally, loosen the lock nut (11) at the adjusting block (8) and adjust the height with the grub screw (12).

11 After the nozzle height has been adjusted, retighten the lock nut (11).

12 After completion of the adjustment, check the nozzle position again.

11

12

8

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Design and function

6.2.4 Nozzle change

Operating data of shut-off nozzles

Adjustment of external pneumatic/hydraulic shut-off cylinder:

Nozzle closed:

The needle touches the nozzle tip, the piston of the shut-off cylinder is in fl oating position - minimum distance to machine > 1mm

Nozzle open (Herzog system):

The needle shoulder touches the nozzle body, the lever is lifted from the needle but does not touch the basic body; the piston of the shut-off cylinder is in its end position at the machine

Nozzle open (Fuchslocher system):

The needle with the crossbar touches the nozzle body, the lever with the rollers is lifted by > 1mm from the crossbar; the piston of the shut-off cylinder is in its end position at the machine

Guide values for lever travel - shut-off cylinder adjusting stroke - see table

Working data Shut-off nozzles

Activationmax. injection fl ow (ccm/sec./cinch/

sec.) (PS)

Nozzle contact force max. (kN/

sh ton)

Back pressure (bar/psi)

Injection pressure max.

(bar/psi)

Tempera-ture max. (°C/°F)

System pressure

pneum./hydr. (bar/psi)

Lever length/stroke (mm/inch)

Herzog Typ SHP Spring

500 / 30,50 70 / 7,87

290 / 4200

3000 / 43511 400 / 752

Herzog Typ HP0 pneum./integrated 500 / 72506,0 / 87

Herzog Typ HP0 pneum./external 500 / 7250 77/3,03 // 17/0,7

Herzog Typ HP0 hydr./external 500 / 7250 40 / 580 77/3,03 // 17/0,7

Herzog Typ HP1 pneum./integrated

1600 / 97,63 130 / 14,61

150 / 2175 6,0 / 87,0

Herzog Typ HP1 pneum./external 150 / 2175 4,0 / 58 77/3,03 // 12/0,5

Herzog Typ HP1 pneum./external 250 / 3625 4,0 / 58 116/4,56 // 22/0,9



Herzog Typ HP2 pneum./integrated3500 / 213,57 180 / 20,23

250 / 3625 6,0 / 87,0


Herzog Typ BHP0 pneum./integrated 1600 / 97,63 130 / 14,61 200 / 2900 6,0 / 87,0

Herzog Typ BHP1 pneum./integrated 500 / 30,50 46 / 5,17 200 / 2900 6,0 / 87,0

ENG Typ L20 pneum./integrated 1000 / 61 100 / 11,24600 / 8700 3000 / 43511 400 / 752 6,0 / 752

ENG Typ L30 pneum./integrated 3500 / 213,57 130 / 14,61

PSG Typ G30 Spring

200 / 12,2 90 / 10,1

250 / 3625

3000 / 43511 400 / 752

PSG Typ G30 pneum./external 250 / 3625 4,0 / 58 35/1,38 // 8/0,31

PSG Typ G30 hydr./external 350 / 5076 30 / 435 35/1,38 // 8/0,31

PSG Typ G48 Spring

500 / 30,50 100 / 11,24

250 / 3625

PSG Typ G48 pneum./external 250 / 3625 6,0 / 87,0 35/1,38 // 5/0,20




PSG Typ G70 Spring1600 / 97,63 130 / 14,61

250 / 3625


Design and function


6.2.4.1 Basic conditions for nozzle change

1 Press the „Manual mode“ button.

2 Set the peripheral equipment (optional) to their initial position and switch them off, following the instructions in the respective operating manuals.

3 Switch off the material feed unit (optional).

( ) For Airmould® nozzle only: close the nitrogen supply to the Airmould® pressure unit.

If necessary, shut down the Airmould® nitrogen generator following the instructions in the separate operating manual.

Shut down the Airmould® pressure unit following the instructions in the separate operating manual.



4 Position the climbing aid in front of the machine.

5 Remove the bulk hopper from the feed opening of the screw barrel.

6 Move the core pullers (optional) out of the mould. „Move out core puller“ indicates that the injection moulding has been removed from the mould or has been ejected by the ejector.

7 Move the clamping plate to its initial position (mould open).

8 If necessary, use the ejector to remove the injection moulding from the mould.

EP6GB0LAEP6DE0LA


Design and function

9 Switch on the screw barrel heating to the currently set operating temperature.

10 Press the „Injection unit back“ button until there is suffi cient space in front of the nozzle to eject the residual plasticised material.


11 Open the protective guard of the nozzle.

12 Place a suitable container in front of the nozzle.

Risk of injury from crushing during closing of the injection guard. Limbs might be crushed or caught between the injection guard and the nozzle plate!

13 Close the protective guard of the nozzle.

14 Eject the residual plasticised at short intervals.

15 Flush the screw barrel with a suitable cleaning compound.

For a list of suitable agents, contact the manufacturer of the plastic you are using.

16 Switch off the water system, the pneumatic system and the Airmould modular system (optional). For details, see chapter „Operation“, section „Shutting down machine“.

17 Press the „Injection unit back“ button until there is suffi cient space for the dismantling of the nozzle.

For Airmould® nozzles only:If the nitrogen system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

For Airmould® nozzle:

( ) Depressurise the Airmould® modular system. For detailed instructions, refer to the operating manual of the Airmould® modular system (chapter „Transport - Installation“, section „Preparation for empty run and locking test without material“).

( ) Set the main switch at the control cabinet of the Airmould® modular system“ to OFF and secure it against inadvertent switching on.

Design and function


17 Switch off the nozzle and screw barrel heating,

18 Switch off the hydraulic system („Hydraulic Stop“ button).

19 Shut off the machine at the main switch and secure the switch with a padlock against inadvertent switching on. The main switch should only be actuated if there is no load.

20 Open the protective guard of the nozzle.


The nozzle must be dismantled and installed by an authorised specialist technician!For the installation, dismantling, relocation, operation or maintenance of machine components that are above head level, always use safe climbing aids and work platforms and strictly adhere to the applicable statutory regulations!Never use machine components as climbing aids! When working at height, wear fall arrest gear!

CAUTIONUse only tools and equipment that cannot cause damage to the components of the machine!

The next steps in the procedure are described below in separate chapters for each nozzle design

EP6GB0LAEP6DE0LA


Design and function

6.2.4.2 Changing “open” nozzleFig. 1 Open nozzle

Requirements: items 1-20 (chapter 6.2.3.1)

1 Dismantle the heating band of the nozzle (1).

2 Remove the nozzle (1) with a hex wrench placed on the hex head (2).

For Airmould® nozzles only:

Remove the union nut of the nitrogen pressure line from the nozzle body.

3 Remove the nozzle body with a hex wrench placed on the hex head (2).

Risk of fi re! Do not use fl ammable solvents!

4 Carefully clean the nozzle (1) and the nozzle body,using a brass or wire brush.

Remove all grease residue from the grooves of the thread.

Cleaning with a gas burner fl ame, by sand blasting or by burning affects the mechanical and technical properties of the components.

The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is cleaning in a blasting system with duroplastic particles.

Risk of injury and damage to components! Only use components that have been supplied by Battenfeld or meet the Battenfeld specifi cations!

CAUTIONDo not use oil-based lubricants that might evaporate!

21

Design and function


5 Treat the threads of the new or cleaned nozzle (1) with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 °C / 662 °F) and neutral towards the material to be processed.

Before installing, check the fi tting faces for damage or wear.

Before inserting a new nozzle (1), check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle (1)).

6 Screw in the nozzle body by hand to the stop but do not tighten it.

7 Screw in the nozzle (1) by hand to the stop but do not tighten it.

8 Mount the heating band of the nozzle (1).

9 Switch on the main switch.

10 Switch on the hydraulic system („Hydraulic Start“ button).

11 Switch on the heating of the nozzle (1) and the screw barrel and heat it to operating temperature.


The operator must ensure that the nozzle is properly mounted and secured as there is a risk of injury, if the nozzle is propelled from the machine!

12 After heating the assembly to operating temperature, fi rmly tighten the nozzle body and the nozzle (1). For tightening torques, see chapter “Technical data”.


Screw on the union nut of the nitrogen pressure line at the nozzle body until there is a clear effort required to tighten it further.

Risk of injury from crushing during closing of the injection guard. Limbs might be caught between the injection guard and the nozzle plate!

13 Close the protective guard of the nozzle (1).


Switch on the main switch at the switch cabinet of the „Airmould® modular system“.

Pressurise the nitrogen pressure line and check the union nut for leakage. For detailed instructions, refer to the operating manual of the „Airmould® modular system“ (chapter „Maintenance, section „Nitrogen leakage“).

EP6GB0LAEP6DE0LA


Design and function

6.2.4.3 Changing Herzog type SHP needle shut-off nozzle spring-controlled

1 Body

2 Needle guide bushing

3 Fixing pin

4 Thrust ring

5 Spring pack

6 Adapter

7 Shut-off needle

8 Nozzle head

9 Heating band

10 Temperature sensor

6

4

3

2

97

10

8

51

Design and function



1 Remove the temperature sensor, if installed.

2 Dismantle the heating band (9) of the nozzle.

3 Screw out the nozzle head (8).

4 Pull out the shut-off needle (7).

5 Unscrew the adapter (6).


6 Carefully clean the components of the needle shut-off nozzle, using a brass or wire brush.





CAUTIONDo not use oil-based lubricants that might evaporate!Components that come into contact with the injection material must not be lubricated!

7 Lubrication of these parts results in contamination of the injection material.

Treat all threads of the new or cleaned needle shut-off nozzle with a high-performance fi tting lubricant. This product must be water-repellant, corrosion-proof, heat-resistant (minimum 350 °C / 662 °F) and neutral towards the material to be processed.

Before installing, check the fi tting faces and the individual components for damage, wear and functioning.

Before inserting a new nozzle, check whether the nozzle radius is dimensioned to fi t the radius of the cast bushing (equal or larger than diameter of nozzle).

EP6GB0LAEP6DE0LA


Design and function

8 Mount the needle shut-off nozzle by completing the above steps in reverse order.

9 Screw in the adapter (6) by hand to the stop but do not tighten it.

10 Push in the shut-off needle (7).

11 Screw in the nozzle head (8) by hand to the stop but do not tighten it.

12 Mount the heating band (9) of the nozzle.

13 Screw in the temperature sensor (10) by hand to the stop but do not tighten it.



16 Switch on the nozzle and screw barrel heating system and heat it to operating temperature.



17 After the assembly has reached operating temperature, tighten the adapter, head and temperature sensor.

Tightening torques: Nozzle head (8) - 220 Nm (162 ft lb)

Fixing pin (3) - 3 Nm (2 ft lb)

Body (1) - 170 Nm (125 ft lb)

For the tightening torque of the adapter (7) see chapter „Technical data“.



Design and function


6.2.4.4 Changing Fuchslocher needle shut-off valve

1 Nozzle body

2 Spring chamber

3 Compression spring

4 Heating band

5 Shut-off needle

6 Nozzle head


1 Unscrew the temperature sensor.

2 Dismantle the heating band (4) from the nozzle head (6).

3 Remove the nozzle body (1) with a hex wrench placed on the hex head.

Do not dismantle the spring chamber (2). The manufacturer shall not be liable for damage caused by incorrect dismantling or installation.

If you suspect that the needle shut-off valve is not working properly, contact our customer service. For addresses, see chapter „Customer service“.

6 52

3 1

4

EP6GB0LAEP6DE0LA


Design and function





The components can however be cleaned in an ultrasound cleaning reactor or in fl uidised bed bath. Also recommended is the cleaning in a blasting system with duroplastic particles.







6 Screw in the nozzle body (1) by hand to the stop but do not tighten it.


8 Screw in the temperature sensor.




Design and function




12 After heating the assembly to operating temperature, fi rmly tighten the nozzle and the nozzle body.

Tightening torques: Nozzle head (6) - 300 to 350 Nm (221 to 258 ft lb)

Nozzle body (1) - 350 to 400 Nm (258 to 295 ft lb)



EP6GB0LAEP6DE0LA


Design and function

6.2.4.5 Changing Herzog type HP needle shut-off nozzle (pneumatically or hydraulically operated) with integrated control cylinder

1 Nozzle head

2 Shut-off needle

3 Fixing pin

4 Lever bolt

5 Levers

6 Screws

7 Heating band


9 Adapter

10 Yoke /adapter ring

11 Control cylinder

1

2

3

6

7

8

9

54 11

10

Design and function



1 Remove the temperature sensor (8), if installed.

2 Remove the heating band (7) of the nozzle.

3 Disconnect the pneumatic and hydraulic hoses (depending on model) from the control cylinder (11) and remove the lever (5).

4 Screw off the nozzle head (1).


6 Screw off the adapter (9).







CAUTIONDo not use oil-based lubricants that might evaporate! Components that come into contact with the injection material must not be lubricated!





EP6GB0LAEP6DE0LA


Design and function



11 Insert the shut-off needle (2).




15 If the control cylinder (11) is not in the required position after being screwed in (e.g. if control cylinder (11) protrudes vertically), loosen the 12 screws (6) by 4 revolutions and then adjust the control cylinder (11) position by turning it clockwise.

16 Tighten two opposite screws (6) and check the gap between the body and the adapter ring (max. permissible gap width 2.5 mm (0.1")).

Turn clockwise

11

6

11

Design and function


17 Tighten all screws cross-wise.

18 Connect the pneumatic and hydraulic hoses (depending on model) to the control cylinder (12) and mount the lever (5).







Tightening torques:



Torque HP0 HP1 HP21st step Prefi xing 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

Designation TorqueHP0 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

EP6GB0LAEP6DE0LA


Design and function

6.2.4.6 Changing Herzog type BHP bolt shut-off nozzle (pneumatically controlled) with integrated control cylinder

1 Nozzle head

2 Bolt shut-off mechanism

3 Lever bolt

4 Levers

5 Screws

6 Heating band


8 Adapter

9 Yoke /adapter ring

10 Control cylinder

11 Shut-off nut

12 Body

1

234

5

89

10

7116

12

Design and function




2 Remove the heating band (6) of the nozzle.

3 Disconnect the pneumatic and hydraulic hoses (depending on model) from the control cylinder (10) and remove the lever (4).



6 Remove the shut-off nut (11).

7 Remove the bolt shut-off mechanism (2).

The bolt and bolt bushing are sometimes diffi cult to remove. Do not apply excessive force. If you encounter any problems in removing these parts, contact Herzog.

Carefully drive out the bolt from the bottom, using a mandrel. Remove the bushing and the bolt from the top.

Align the grooves of the bolt bushing with the positioning pin to the body.

EP6GB0LAEP6DE0LA


Design and function


8 Carefully clean the components of the nozzle, using a brass or wire brush.










10 Mount the bolt shut-off nozzle by completing the above steps in reverse order.


12 Insert the bolt lock (2) and tighten the shut-off nut (11).




16 Connect the pneumatic and hydraulic hoses (depending on model) to the control cylinder (10).




Design and function





Tightening torques: Shut-off nut (11) - 180 Nm (133 ft lb)

Screws (5) - 25 Nm (18 ft lb)

Bolt screws (11) - 30 Nm (22 ft lb)

Nozzle head (1) - 150 Nm (111 ft lb)



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Design and function

6.2.4.7 Changing Herzog type HP needle shut-off nozzle (pneumatically or hydraulically operated)

1 Adapter


3 Heating band

4 Nozzle head

5 Screws

6 Rods



2 Dismantle the rods (6).

3 Dismantle the heating band (3) of the nozzle.


5 Pull out the shut-off needle.


6

5

4

3

2 1

Design and function
















12 Screw in the head (1) by hand to the stop but do not tighten it.



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Design and function







Tightening torques:

19 Mount the rods (6).



Designation TorqueHP0 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

Design and function


Flange screws

Rods

Gap between body and adapter ring

The nozzle is supplied as pre-assembled unit. The fi nal assembly is done directly on the machine.

After the rods with the nozzle has been aligned, tighten the fl ange screws crosswise in 4 steps. The gap between the body and the adapter ring might measure 0.5 to 2.5 mm (0.02 and 0.1").

Tighten the screws crosswise.

1st tightening step = tighten all screws equally (preliminary fi xture)

2nd tightening step = tighten with 70% of prescribed torque

3rd tightening step = tighten with 90% of prescribed torque

4rth tightening step = tighten with 12 Nm (9 ft lb)

EP6GB0LAEP6DE0LA


Design and function

6.2.4.8 Changing Fuchsloser needle shut-off nozzle (pneumatically or hydraulically operated)

1 Nozzle body

2 Thrust ring

3 Heating band

4 Nozzle head

5 Shut-off needle

6 Fork



2 Dismantle the heating band (3).

3 Remove the rods from the fork (6).



6 Screw out the nozzle body (1).

6

5

4

3

2 1

Design and function


















14 Screw in the temperature sensor by hand to the stop but do not tighten it.




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Design and function






Design and function


6.2.4.9 ENG pneumatic needle shut-off nozzle with integrated control cylinder

1 Nozzle body

2 Control cylinder

3 Rods

4 Nozzle head

5 Body

6 Clamping nut



2 Dismantle the heating band.

3 Remove the rods (3).


5 Pull out the shut-off needle.

6 Screw out the nozzle body (1).

5

4

3

2

1

6

EP6GB0LAEP6DE0LA


Design and function














11 Insert the shut-off needle.


13 Mount the heating band of the nozzle.

14 Screw in the temperature sensor by hand to the stop but do not tighten it.




Design and function





Tightening torques: Clamping nut (6) L20 - 600 Nm (443 ft lb)

L30 - 1200 Nm (885 ft lb) Nozzle head (4) L20 - 250 Nm (184 ft lb)

L30 - 600 Nm (443 ft lb)



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Design and function

6.2.5 Dismantling the screw barrel / screw6.2.5.1 Dismantling screw







1 Remove all residual material from the screw barrel by ejecting it.


Design and function


1

2

3

2

4

3 Detach the screw from the screw coupling. Loosen the 4 screws (1) of the screw coupling (2) and remove the 2 feather keys (3).


EP6GB0LAEP6DE0LA


Design and function

5 Press the button for injection piston movement and move the screw (4) to its forward position.

6 Press the button for injection piston movement and move the screw (4) to its back position. Remove the screw coupling (2).

2

4

4

Design and function


7 Insert the 2 lifting bolts (5).

8 Remove the 4 screws (6).

5

6

EP6GB0LAEP6DE0LA


Design and function

9 Attach the screw barrel to the crane.

10 Ensure that the water hoses (7), the barrel heating cable (8) and the sensor of the traverse cooling (9) are not jammed or squeezed and lift the screw barrel.

9

8

7

Design and function


CAUTIONEnsure that the screw barrel is in a horizontal position when being lifted!

The load capacity of the lifting gear and tackle must match the weight of the screw barrel!Do not use Nylon lifting tackle. The lifting tackle must be resistant to the temperature of the screw barrel!

11 Slowly lift the screw barrel with the crane.

12 Lift the screw barrel until the lower fi xing screws (10) of the fl ange can be inserted into the upper holes of the traverse (11). Insert the 2 fi xing screws (10).

11

10

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Design and function


13 The screw (4) can now be pulled from the screw barrel.

14 When installing the screw in the barrel, ensure that the sealing ring (12) is correctly mounted.

4

12 4 12 4 12 4

Design and function


6.2.5.2 Dismantling the screw barrel







1 Remove all residual material from the screw barrel, using a water jet.


3 Unscrew guard plate (1)

1

EP6GB0LAEP6DE0LA


Design and function

4

2

5

3

4 Disconnect the water hoses (2), the barrel heating cable (2), the sensor of the traverse cooling (4) and the sensor of the barrel heating (5).

Design and function


5 Detach the screw from the screw coupling. Loosen the 4 screws (6) of the screw coupling (7) and remove the 2 feather keys (8).


6

7

8

7

9

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Design and function

7 Press the button for injection piston movement and move the screw (9) to its forward position.

8 Press the button for injection piston movement and move the screw (9) to its back position. Remove the screw coupling (7).

9

7

9

Design and function


9 Insert the 2 lifting bolts (10).

10 Remove the 4 screws (11).

10

11

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Design and function

11 Attach the screw barrel to the crane.

CAUTIONEnsure that the screw barrel is in a horizontal position when being lifted!

The load capacity of the lifting gear and tackle must match the weight of the screw barrel!Do not use Nylon lifting tackle. The lifting tackle must be resistant to the temperature of the screw barrel!

12 Slowly lift the screw barrel with the crane.


Design and function


13 The screw barrel can now be removed from the guide.

EP6GB0LAEP6DE0LA


Design and function

6.2.8 Cleaning the screw barrel (change of injection material)To meet the ever more stringent quality requirement for plastic products, frequent and careful cleaning of all components that are in direct contact with the material is important.

6.2.9 Removal with high-grade polyethyleneThis method ensures that nearly all previously processed material is removed from the unit. The polyethylene itself must be pushed out of the screw unit by the new material. In most cases, there is no need for manual cleaning.

6.2.10 Material removal with cleaning granulesThe cleaning granules are normally made of a transparent, high-molecular thermoplastic material that becomes elastic but not fl uid at temperatures around 100 °C (212 °F). This material does not melt or attach itself to the equipment. It works like an elastic pusher, pushing all residual material from the previous batch from the screw barrel. In most cases, there is no need for manual cleaning.

Prior to cleaning, remove the shut-off and the open nozzle and lower the nozzle temperature. The temperature of the screw barrel should be kept at below 300 °C / 572 °F), while the injection pressure is to to the lowest value. If required, it can be increased slightly during the process.

6.2.11 Cleaning the screw barrel

CAUTIONIt is strictly forbidden to clean the screw with a gas burner, by sand blasting or by burning!

These methods would have a negative effect on the mechanical and technological properties of the screw. Cleaning by such methods shall void all warranty cover.

Clean the screw only with a brass brush. The use of a wire brush is prohibited, as it could damage the surface of the part. Also recommended is cleaning in a blasting system with duroplastic particles.

The screw barrel is cleaned with a rotation brass brush attached to a rod. It can be operated by a power drill or similar tool.

6.2.12 StorageTo store the cleaned screw and screw barrel, we recommend fi lling the barrel with little blue gel (approx. 200 g / 7 oz) or KC desiccant beads (from Kalichemie) and sealing all openings. The screws should be packed in plastic bags that also contain a little blue gel. This measure helps prevent corrosion during storage.

Design and function

EP6GB0MAEP6DE0MA0510WT Chapter 6.3 - 1

6.3 Hydraulic system

6.3.1 GeneralThe hydraulic system of the injection moulding machine offers a number of advantages to the operator:

• Hydraulic system is easily accessible.

• Constant-displacement pump driven by an energy-effi cient server motor allows for smooth yet high-precision movements.

• The hydraulic components are installed in such a way that the lengths of pipe and hose lines is kept to a minimum.

• Easy to maintain.

• The full fl ow fi ltration ensure that the oil quality is kept at a high level for a long period of time.

6.3.2 Pump unitThe pump unit consists of a servo motor, the pump carrier, the coupling and a constant-displacement pump.

A pressure oil line connects the pump unit with the pump block. The leak oil line and a suction oil line lead to the oil tank.

There is no valve installed between the hydraulic tank and the pump unit.

6.3.3 Hydraulic tankThe hydraulic tank is screwed into the machine frame and is equipped with a fi ller cap with oil fi ller screen, air fi lters, an electrically monitored oil level indictor and a temperature sensor.

The hydraulic tank must only be fi lled through the oil fi ller screen of the fi ller cap. This opening is accessible in the machine frame near the front plate.

The hydraulic oil must be pre-fi ltered in a mobile fi lter unit (fi lter size 3 μm, cleanliness class 17/15/12 according to ISO 4406, class 6 according to NAS 1638).

The hydraulic tank is equipped with connections for an external oil fi lter unit.

To clean the hydraulic tank, remove the tank cover.

EP6GB0MAEP6DE0MA


Design and function

6.3.4 Return fi lterThe return fi lter is equipped with a contamination sensor. if this sensor is triggered, an error message is displayed on the screen of the control unit.

Change the fi lter cartridge (prod. no. MB628) at the next available opportunity (break in production run, e.g. at the end of a shift). If no fi lter cartridges are available in stock reorder them as soon as possible.

As a rule, always change the fi lter cartridge each time the oil is changed. If it is necessary to change the oil prior to the next change interval (e.g. due to an error message or a negative oil analysis), also replace the fi lter cartridge.

Utmost cleanliness is essential. The contamination sensor includes a cold start disabler, which means that the respective switch is disabled at oil temperatures below 27 °C (80.6 °F).

Changing the fi lter cartridge

• Switch off the IMM and wait until the system is completely depressurised.

IF THE HYDRAULIC SYSTEM IS NOT DEPRESSURISED PRIOR TO STARTING WORK ON THE UNIT, THERE IS A SERIOUS RISK OF INJURY AND DAMAGE TO THE EQUIPMENT AS IT MIGHT EXPLODE!RISK OF INJURY FROM BURNS! AT OIL TEMPERATURES ABOVE 60 °C (140 °F), WEAR SUITABLE PROTECTIVE CLOTHING!

• Unscrew the fi lter cap (3).

• Pull the fi lter cartridge (1) with the fi lter pot (4), holding it by the bracket.

• Remove the fi lter cartridge (1). Examine the surface for dirt particles. Such particles might indicate that components are damaged.

• Dispose of the fi lter cartridge (1).

• Before installing the fi lter cartridge, check it again to ensure that its designation corresponds to that of the removed fi lter cartridge.

3

2

1

4

Design and function

EP6GB0MAEP6DE0MA0510WT Chapter 6.3 - 3

CAUTIONDo not clean or re-use the fi lter cartridge!

• Remove the fi lter cartridge. The fi lter cartridge cannot be cleaned. Any attempt to clean the fi lter cartridge results in damage to the fi lter material, so that contaminations are not held back by the cartridge.

• Clean the inside of the fi lter pot (4) with a suitable agent (e.g. white spirit, petroleum), ensuring that no dirt is inadvertently moved to the clean side of the system.

• Examine the fi lter for mechanical damage, especially on the sealing faces and the threads. Replace damaged parts. Check the O-rings and replace damaged O-rings.

CAUTIONIf damaged parts are not replaced and if the fi lter is not in proper working order, there is a risk of damage to other components of the system and impaired performance!

6.3.5 Oil cooler (optional)In the oil cooler, cooling water is fed through pipelines inside the cooler, cooling down the hydraulic oil, so that the hydraulic oil can be kept at the required temperature by controlling the cooling water fl ow and temperature.

Before connecting the oil cooler to the water circuit, ensure that the water quality meets the requirements specifi ed in chapter „Maintenance“. If the water does not meet these specifi cations, install a water fi lter (optional) to ensure that the cooling water stop valve works properly.

This valve controls the water fl ow in the circuit and keeps the oil at a constant temperature.

In units with closed cooling circuit (optional), the oil cooler is connected to the central heat exchanger, so that there should be no need for separate fi ltration.

6.3.6 Indicating and control deviceThe oil temperature is measured inside the oil tank. The measured temperature is displayed on the screen of the machine control system.

EP6GB0MAEP6DE0MA


Design and function

6.3.7 Pressure settingsThe hydraulic pressure for all functions is controlled by the servo drive based on the pressure settings entered on the screen in bar (psi).

6.3.8 Speed settingsThe hydraulic speeds for all functions are controlled by the servo drive and entered on the screen in absolute values (mm/sec, inch/sec).

6.3.9 Hydraulic core pullerThe hydraulic core puller (optional) consists of a base plate on which the necessary hydraulic valve are mounted and that contains all necessary consumer connections (DN 6).

The hose lines and fi ttings for the connection of the core puller cylinder at the mould side are not included in the scope of delivery.

Please note that the hydraulic pressure can reach 250 bar (3625 psi). All connecting elements must thus be rated for this pressure level!

The hydraulic core pullers must be connected and commissioned by a specialist hydraulic technician! Always strictly adhere to the safety instructions in chapter „Safety“!

Design and function

EP6GB0NAEP6DE0NB0510WT Chapter 6.4 - 1



Application

The UNIFEED material feed unit (optional) has been designed for use in conjunction with a plastics processing machine and is installed directly above the screw barrel, replacing the bulk hopper.

It is particularly safe, as it contains no moving parts. The unit is also extremely easy and safe to use and service.

The UNIFEED unit is the preferred feed option for the following materials:

PE-HD, PE-LD, PS, PA, PA + GF, PP, ABS, POM, PPO.

Design and function

2

3

4

5

6

7

8

9

10

11

12

1

If the granule level in the container drops during metering to a level below the capacitive limit switch (6), the pneumatic valve (2) is opened. Compressed air is blown through the air nozzle (9) into the suction pipes (11), generating a vacuum, which extends into the suction chamber (11) and the container pipe (4).

Due to the vacuum, a granule-air mixture is taken up through the suction lance (5) and the suction hose (1) into the container pipe (4). The granules are separated in a primary fi lter (8) from the suction air.

Subsequently, the air is cleaned in a secondary fi lter (12) from dust particles and is released from the material feed unit.

EP6GB0NAEP6DE0NB


Design and function

As the level of the material in the feed unit reaches the level of the capacitive limit switch, the air valve is switched off, shutting down the compressed air supply, and the fi lling process is terminated.

At the end of the fi lling process, a small amount of compressed air is fed in pulses into the suction chamber (10), cleaning the primary fi lter from dust particles.

Processing of regenerated granules

In general, the UNIFEED material feed unit is suitable for the feeding of regenerated material in conjunction with new granule material. The grain size must not exceed 3 to 4 mm (0.12 to 0.16").

As regenerated material contains more dust particles, the fi lter becomes clogged up quicker, so that it must be cleaned at shorter intervals.

6.4.2 Pneumatic core pullerThe pneumatic core puller (optional) consists of an electrically powered 5/2 pneumatic valve including all consumer connections made in plastic (DN 6 (0.24")).

This functional module is mounted on the centre console or on the medium beam of the clamping plate. The equipment for the connection of the core puller cylinder at the mould side is not included in the scope of delivery.

CAUTIONPlease note that the device must be operated with dried compressed air and that the pneumatic pressure must not exceed 6 bar (87 psi). All connecting elements must thus be rated for this pressure level!

Structure and function

HC4GB0OBHC4GB0OA0510WT Chapter 6.5 - 1

6.5 AirmouldThe Airmould unit (option) enables the manufacture of high quality injection moulded articles withgas voids by gas injection. For this reason, the injection moulding machine, for example, may beoperated with shorter cycle times and lower clamping forces.

The defining feature of gas injection is the filling of the mould cavity with two fluids. One fluid isthe polymer melt and the other is a gas, as a rule nitrogen (N2).

Danger of death! Only use nitrogen (N2) gas!

It must be ensured that the plastic processed does not return aggressive or contaminating gasesto the equipment.

The gas may be injected either via the machine nozzle or through needles in the mould (injectionmodules).

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 anelectronic control unit integrated into the IMM "Control unit".

The pressure regulators (1) for regulation of the gas pressure in the machine nozzle or mouldneedles, are compactly built units and can thus be positioned very close to the gas injectionpoint. Four pressure regulators can be controlled by one standard electrical control.

HC4GB0OBHC4GB0OA



The main parts of the pressure generator (2) are a high pressure compressor, drive motor, gasbag, and accumulator bottles.

A nitrogen generator can be arranged as a separate unit or integrated into the pressure generator,as the customer wishes.


HC6GB0QAHC6DE0QA017WT1 Chapter 6.7 - 1

6.7 UNILOG B6 control

6.7.1 General informationUNILOG B6 is a new generation of control units which sets the standard regarding operatorfriendlinesss, speed and precision.

The continuity of the Battenfeld philosophy and symbolism regarding operation is ensured bytaking over the components from the previous control system - with an additional enlargement ofthe graphical user interface.

A powerful system concept ideally adapted to the requirements of the hydraulic / sensor systempromotes quick and precise movements of all machine axes. The precise analysis of allimportent process variables provides the user with the control and supervision he needs fordemanding tasks.

6.7.2 Control panelThe control panel is divided into:

• 15"-TFT colour monitor withunrestricted touch-screen functionsfor operation and display

• 2 rows with soft keys to select themachine functions

• 48 membrane keys for operatingthe machine axes and the optionalequipment

• Space for another 7 optionalmechanical switches / keys

• 10 luminous ring membrane keysare available for the main machinefunctions (drive, heaters, operatingmodes).

• 2 USB interfaces can be used forthe connection of data carriers (e.g.USB stick, printer, keyboard) or asan access system in combinationwith a password.

• More interfaces (2 USB and 2Ethernet interfaces) are located atthe rear side in the switch cabinet.

HC6GB0QAHC6DE0QA

017WT1Chapter 6.7- 2


6.7.3 Explanation of the pictureFlexibility

UNILOG B6 is a control concept which meets all demands concerning flexibility.

With the free core puller programming, the user can, for example, quickly and flexibly set corepuller sequences for different moulds. In standard operation, up to 8 core puller sequences canbe parameterised with a large number of logical operations.



Holding pressure

The combination of tabular input and graphic represenation facilitates the setting of the machinewith the number of profile points being selected by ticking. A status bar on the extreme right ofthe screen will quickly inform you on the current machine status. Furthermore, two configurablestatus bars are available. By entering the machine settings in physical units and storing them onan USB stick, machine data records can be exchanged among machines of different size.

HC6GB0QAHC6DE0QA



Actual value graphics

The most important means to assess the injection moulding process is the graphicrepresentation of pressure and speed developments during the injection or holding pressurephase. The clear representation by the selection of curve numbers, different colours and thenumerical representation of peak values and actual values within the change-over point enables aprocess analysis at a glance.



Cycle time analysis

Analysis at a glance. The configurable cycle time analysis can be used for process optimisationand, at a glance, shows the effects in the value change cycle to individual movements and/or thetotal cycle. A complete overview is given by determining a reference cycle compared to theprevious and the current cycle.

HC6GB0QAHC6DE0QA



Alarm system

The production process can be backtraced by means of a comprehensive alarm / logging conceptwith different filtering possibilities. Reaction times in the event of plant failures are shortened bythe automatic dispatch of email messages.

6.7.4 Saving / PrintingUSB interfaces

Data / printouts can be stored / sent to USB data carriers and/or USB printers compatible withWinXPTM by means of 2 USB interfaces located laterally on the operator panel and 2 other USBinterfaces in the switch cabinet.

Ethernet interfaces

Two Ethernet interfaces with RJ45 connections are available in the machine switch cabinet for theintegration 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.



6.7.5 Control componentsSystem structure

Overview of the Unilog B6 hardware structure

Touch display unit and key unit

Automation PC

X2X I/O system

X2X Link connection

Short-distance link connection (SDL)

Ethernet Powerlink connection (EPL)

HC6GB0QAHC6DE0QA



Touch display unit AP9xx

The display unit is composed of two components: an automation panel device and an automationpanel link plug-in module. These two components, plugged together, build the complete displayunit. The resolution is 1024 x 768.

Automation panel link plug-in module

Automation panel 900

Cleaning:

The display unit may be cleaned only while the device is switched off in order to avoid the releaseof 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 agentdirectly on the automation panel device but spray it on the cloth! Under no circumstances useaggressive solvents, chemicals, scouring agents, compressed air, or steam jet.

Clean the display with the touch screen at regular intervals.



Automation panel link plug-in module SDL

The automation panel link plug-in module is the interface between an automation PC 620 and anautomation panel 9xx. Graphic signals of an industrial PC (e.g. automation PC 260 monitor /panel output) are received, processed, and passed on to the automation panel 9xx. In theopposite direction, the touch screen, USB and SDL data, for example, are transferred to therespective interface of the industrial PC (e.g. automation PC 620). By means of simple slide-intechnique, this plug-in module is plugged into the slide-in slot of the automation panel 900 andfixed to the automation panel by means of the two fixing screws (max. tightening torque 0.5 Nm).

Display cable SDL cable 5CASDL.0xxx-00Fixing screws

Voltage supply+24 VDC In

Panel IN(via SDL)

This cable is necessary for the transmission of the graphic / touch screen / USB signals betweendisplay unit (automation panel link plug-in module) and automation PC.

CAUTIONThe SDL cable may be connected and disconnected in the dead state only.

Pin assignment

CoatCoat

HC6GB0QAHC6DE0QA



Key unit 5E9000.xx

Is used to operate the basic machine functions and special equipment. Due to the slide-in striptechnique, it can be easily adapted to customer wishes.

• Voltage supply: +24 V DC

• Bus interface: 2 x Ethernet Powerlink (EPL)



Automation PC 620

The APC620 with Intel® Pentium® M processors and Intel® 855GME chipset is available forapplications with the highest demands in terms of processor performance. These processors,which were especially developped for mobile computing, offers many advantages for industrialuse, too. High computer power is combined with low power input. The chip set includes anintegrated 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.

Ap Link slot

PCI Slot 2

PCI Slot 1

Add-On interface slot

MIC, Line IN,Line OUT

Monitor / panel SDL(Smart Display LinK) DVI

Voltage supply+24 VDC

USB1, USB2

Ethernet 2

Ethernet 1

COM2

COM1

Heat sink

Heat sink seal

Warning

HC6GB0QAHC6DE0QA



Battery:

A lithium battery (3 V, 950 mAh) buffers the internal real-time clock (RTC) as well as individuallystored BIOS settings and is located under the black cover. The buffer duration of the battery is atleast 4 years (at 50°C, 8.5 µA of the components to be supplied and a self-discharge of 40%).

Per

man

ent m

agne

t

Lower slide-In slot 1 unlocking (1)

LED for: Power, HDD, Link1, Link2

Slide-In Slot 1 Drive slot

Add-On drive slot

Compact Flash slot

Power key

Reset key

PS/2 keyboard or PS/2 mouse

Battery

Serial number label

Lower slide-In slot 1 unlocking (1)

Hardware security key

(1) Before unlocking, the side cover of the Automation PC 620 must be closed



I/O modules

Three basic elements form a single module: Bus module - electronic module - field terminal

1

2

3

4

5

6

7

8

1 Easy installation - ingenious top-hat rail installation for optimum system handling

2 Stable triangle arrangement - direct connection between bus module and terminal block

3 Wide range of products - allows optimum adaptation for every task

4 Galvanically insulated - reliable operation under the toughest conditions

5 Diagnosis - on-site visual diagnosis, remote via software and electronic type plate

6 12x field terminal - ensures maximum packing density

7 Push-in terminals - no tools required for the handling of all standard connection crosssections

8 Coding - seamless works and customer coding

HC6GB0QAHC6DE0QA



X20BR9300

The X20 System is connected to the X2X Link with the bus receiver BR9300. The module isequipped with a feed for the X2X Link and the internal I/O supply.

X20DI9371

The module DI9371 has 12 inputs in single conductor technology. The DI9371 is designed for sinkinput wiring.

X20DO6322

The module DO6322 has six outputs in single or doubleconductor technology. The X20 standardterminal can be used 6x for continuous single conductor wiring. Double conductor wiring ispossible with the 12x terminal. The DO6322 is designed for source output wiring. The nominaloutput current is 0.5 A.

X20DO9322

The module DO9322 has 12 inputs in 1-conductor technology. The DO9322 is designed forsource 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 2A. The output supply is fed directly at the module. This means that no additional feed module isnecessary. There is no connection from the module to the I/O supply potential on the busmodule.

X20AI4632

The module AI4632 has four inputs with 16-bit digital converter resolution. It can be switchedbetween current and voltage signal (+/- 10 V DC) with the aid of different connection terminals.

X20AO4632

The module AO4632 has four outputs with 16-bit digital converter resolution. It can be switchedbetween current and voltage signal (+/- 10 V DC) with the aid of different connection terminals.



X20AT6402

The module AT6402 has six inputs for J, K, N and S thermocouple sensors. A terminaltemperature compensation is integrated in the module.

X20DC2395

The module DC2395 is a multifunctional counter module. It can be connected from an SSIsensor, an ABR sensor, two AB sensors or four event counters. Two outputs are available forpulse width modulation. The functions can also be combined.

X20PS4951

The module PS4951 has four +/-10 V DC voltage supply channels for the potentiometer supply.

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Operation

HC6GB0RAHC6DE0RA017WT1 Chapter 7 - 1

7 Operation

7.1 General information

For a number of reasons we would recommend commissioning of the IMM by Battenfeldpersonnel. 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 connectionfaults.

• 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 magneticquick-action mould mounting systems (option), cardiac pacemakers, hearing aids, or disksetc. will be impaired!

These magnetic fields will still be present after switching off the machine at the main switch. Onlyafter demagnetising the magnetic modules will the magnetic fields be neutralised, i.e. the hazardwill no longer be present.

CAUTIONThe tiebar nuts may loosen due to the constantly changing loads. Therefore, the clampingplates of the tiebar nuts must be tightened and checked for security after the first 100operating hours.

CAUTIONEvery 2500 operating hours, the barrel heater bands must be checked for tightness atoperating temperatures!

Check the nitrogen pressure in the pressure vessel (option) at regular intervals asdescribed in this chapter!

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017WT1Chapter 7 - 2

Operation

7.2 Initial start-up1 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 screwbarrel heating

11 Ensure that no easily combustible materials, e.g. styrofoam, rags etc., or explosive airmixtures are near the inlets of the radial fans (option).

12 Lubricate lubrication points, as described in the "Transport - Installation" chapter

The oil level must be checked before the first start-up and, if necessary, oil must be filledin or refilled in the "Axial bearing" of injection unit 8800 and if the servo-motor option isinstalled.

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 operatingmanual.

14 Switch on drive ("Drive On" key).

The standard machine has an oil preheating system, and can not be run until a hydraulicoil’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 allalarm messages" section).

16 Mount the mould as described in the "Transport - Installation" chapter and adjust theclamping 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

Operation


19 Open and close the safety gate and purge guard (to test the safety gate monitoring circuit)

It is forbidden to stand on the machine or to reach into the injection unit during operation!

20 Carry out the test run and interlock test as described in the "Transport - Installation"chapter

21 Carry out the test run without / with material as described in the present section.

22 Select the operating mode and start the machine.

7.3 Starting the machine after EMERGENCY STOPThe emergency stop button is a safety switch for shutting the machine down quickly in the caseof danger. If it has been operated, it must be released after the fault or the cause of the externalemergency stop (periphery, e.g. the robot) has been cleared, by turning it in the direction of thearrow. Then the machine is switched on again as described in the paragraph "Operation", and ifnecessary, 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, corepuller (option) out.

7.4 Checking the nitrogen pressureCheck the nitrogen pressure in the pressure vessel (option) before and during operation. In casethe nitrogen pressure falls short of the indicated value (see name plate), nitrogen has to berefilled.

The safety regulations in the chapter "Safety" are to be followed without fail!Work at pressure vessels may only be carried out by specially trained personnel!Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like)must not be carried out until the hydraulic pressure (oil) has been released!Risk of explosion! Only use nitrogen "N2" as gas!

For instructions on how to refill, reduce and check the nitrogen pressure, please refer to the"Transport - Installation" chapter.

1 Check at least once within the first 40 operating hours. Major losses in nitrogen willimmediately be detected and be compensated.

2 In case no losses have been detected during the first inspection, the next inspection is tobe carried out after 500 operating hours.

3 After this inspection further inspections may be carried out at an interval of 1000 operatinghours.

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017WT1Chapter 7 - 4

Operation

7.5 Test run without materialAfter commissioning or changing the mould, the movements of the various units should be testedbefore 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 properlyinstalled 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 turnclockwise.

6 Open the water supply from the cooling system to the individual users (oil cooler, coolingwater flow governor, etc.) - commissioning only

7 Open the air supply from the compressed air system to the air supply unit (option),UNIFEED material feeder (option), mechanical scotch (option) -commissioning only


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 apower-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 isheated up to a minimum of 40 °C (104 °F)

Start the pump without load and run it for a few seconds to allow for adequate lubrication.

11 Switch on bypass filtration unit (option).

Operation


Before operating the machine the safety regulations in the operating manual(s) of anyperipheral equipment must be followed without fail!

12 Commission peripheral equipment (option) according to the operating manuals and setthem to the starting position, i.e. the position in which no damage to the devices or tomachine components is possible.

13 Clear any error messages which appear (see "UNILOG B6 User’s Manual", "List of allalarm 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 injectioncycle. Otherwise the mould can possibly be overpacked. When opening the mould andusing magnetic quick-action mould mounting systems (option) in particular the chuckingpower can be exceeded.For moulds with a smaller base the ejector force may exceed the retention force of theclamping elements which will cause the mould to disengage.

During operation "without material" it is necessary that no shot volume is entered, thus theset value is 0. In this, case the screw is only to be retracted by means of decompressionin order to avoid the injection of material.

Set the set values for "Injection", "Locking force" and "Ejector" as low as possible for anacceptable injection cycle. Otherwise forces may be present when opening the mouldwhich can possibly exceed the limit range of the clamping elements!

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017WT1Chapter 7 - 6

Operation

Fire hazard! No smoking! Make sure that there are no flammable liquids, open flame, etc.near the screw barrel heating or barrel cooling (option)!

No drawn-in material or explosive air mixtures may be near the inlet area of the radial fansto 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)1

Operation


20 Press "Automatic mode" key.

Operating and other personnel may only stand in front of the machine on the operator’sside 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 openedautomatically 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 safetygates.

The "Fully automatic" and "Semiautomatic" modes are interrupted by pressing the"Manual mode" key or an emergency stop button.

Any leaks which arise in the first few operating hours can usually be cured simply bytightening 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 ofproduction initiated" is displayed. After the cycle has been interrupted, further operationcan be initiated by pressing the "Close mould" key.

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017WT1Chapter 7 - 8

Operation

7.6 Filling the material hopper

1 Make sure that the main switch is switched off and secured against unauthorisedreconnection.

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 theaverage body height, climbing aids and working platforms which meet the legal safetyrequirements 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 openmaterial bags should be avoided.

Follow the plastic manufacturers’ instructions!When processing plastics which give rise to harmful gases dusts or vapours, the proprietorof the machine has a duty to provide suitable extraction for the protection of operatingpersonnel!

CAUTIONThe operator has a duty to ensure no foreign bodies enter the material hopper of barrelthroat!

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.

Operation


7.7 Test run with material

The safety regulations in the chapter "Safety" are to be followed without fail!

1 Prepare the machine as described in chapter "Test run without material", steps 1 to 3.

2 Fill material as described in section "Filling the material hopper".

3 Prepare the machine as described in chapter "Test run without material", steps 4 to 18.

4 Preselect the metering profile (shot volume) correspondingly.


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.

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Operation

9 Select the desired program "Automatic” or "Semiautomatic”

Depending on the program selection either press the "Close mould" key or close thesafety gate (see step 22 in the "Test run without material" section) to start themachine.

In this way several cycles are run.

The movements of the various units, the settings and the quality of the mouldings are now to bechecked. Depending on the application, appropriate corrections are made to the various setvalues 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 beprinted 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

CAUTIONTo prevent set value entries by unauthorised persons, the user must log off after finishingsetting!

10.1 An activation of the key symbol opens the window for "System password".

If you want to interrupt or finish your work at the control unit, you will have to logout first.This procedure prevents unauthorised input at the control unit.

10.2 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".

Operation


7.8 Operation

The operation of the machine does not differ from the procedure described in paragraph "Test runwith material" and the procedures described in this section.

After each shutdown and before each start-up of the machine, the safety devices have to bechecked after switching on the main switch as described in the "Transport - Installation"chapter!The safety regulations in the chapter "Safety" are to be followed without fail!

For the first few hours in which the machine is used under production conditions, the followingshould 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 °Fand 122 °F).

The current oil temperature will be displayed on the "Hydraulics" screen page.

2 The proper fit of the tiebar nuts.

The tiebar nuts may loosen due to the constantly changing loads. Therefore, the clampingplates of the tiebar nuts must be tightened and checked for security after the first 100operating hours.

3 The screw barrel heater bands

The barrel heater bands must be checked every 2500 operating hours for security atoperating temperatures.

4 The nitrogen pressure within the pressure vessel (option); see "Checking the nitrogenpressure" chapter.

Periodical checks should be performed during operation at regular intervals and according to theprocedure described in the "Maintenance" chapter.

Visible defects are to be remedied immediately.

Remedy damage immediately. Hydraulic oils escaping at high pressure can cause severeinjuries and fires!This applies especially to hydraulic fittings and hose assemblies.

HC6GB0RAHC6DE0RA


Operation

7.9 Shutting down the machine

1 Press the "Manual operation" key.

2 Set peripheral equipment (option) to the starting position and switch off any peripheralequipment 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 themoulding(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 atshort 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) frompressure

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. Themain switch should be operated whenever possible without applied load.

Operation


7.10 Extended shutdown

1 Shut down the machine as described in "Shutting the machine down”.

Swing the material hopper to the emptying position and fill the remaining material into anappropriate container.

2 First free the screw barrel and the screw from the remaining melt and purge out withpolyethylene.

3 Depending on the material to be processed, the nozzle and the screw must be removedand cleaned.

4 Preserve the cavities of the mould according to the manufacturer’s instructions.

5 For a hydraulic system with integrated pressure accumulator (option) deflate the nitrogenas 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 anticorrosiveagent

HC6GB0RAHC6DE0RA


Operation

7.11 Shut down procedure

1 Shut down the machine as described in "Shutting the machine down”, steps 1 to 10

2 Preserve the cavities of the mould according to the manufacturer’s instructions.

7.11.1 Dismantling the mouldIn this paragraph the dismantling of a mould fastened with mould clamps is described. Thedismantling of a mould fastened with a quick-action mould mounting system basicallycorresponds to the following description. The only differences will be in the Remove mould of theclamping platen / nozzle platen paragraphs. To this end use the appropriate control elements atthe operator panel. See also paragraph "Mould mounting using quick-action mould mountingsystems" in the "Transport -Installation" chapter

1 Press the "Mould Close" key and close the mould.

The mould may only be dismantled by an authorised skilled technician!

2 Disconnect the ejector coupling (mould to hydraulic ejector cylinder).

Burning hazard if touched! At mould temperatures above 60 °C (60,00 °C) wear appropriatePPE!

3.3 Let the mould cool down to a safe temperature (material dependent).

3.4 Prepare the mould for dismantling (Disconnect cooling hoses, heating cables etc.).

Operation


5 Mount the safety strap holding the two mould halves together.

The safe working load of the lifting equipment must equal or exceed the weight of themould!

6 Mount the lifting gear at the mould.

7 Slightly tension the lifting gear.

8 Press the "Setting" key.

9 Loosen the mounting elements of the mould on the clamping platen.

10 Move the clamping platen back.

11 Loosen the mounting elements of the mould on the nozzle platen.

12 Remove them from the centering hole in the nozzle platen.

HC6GB0RAHC6DE0RA


Operation

Danger of death! It must be ensured that no persons stand or linger under the suspendedload!

13 Lift the mould horizontally out of the opened clamping unit.

14 Protect the mould according to the mouldmaker’s instructions and prepare it for storage.

7.11.2 Further measures for shutting down1 Let the heating elements and their guardings, temperature control units and their flow and

return lines and their couplings and mounting elements cool down to a safe temperature.

2 Move the piston rods of the hydraulic cylinders in the setting mode as far as possible intothe 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 bemoved 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. Themanufacturer’s instructions are to be followed without fail!

5 Dismantle nozzle (and nozzle head) as well as screw and screw barrel and clean them.

Operation


7.11.3 Emptying the hydraulic system

Work at the hydraulic system may only be carried out by a skilled hydraulic technician!

1 For a hydraulic system with integrated pressure accumulator (option) deflate the nitrogenas described in section "Transport - Installation".

Burning hazard if touched! At oil temperatures above 50 °C (50,00 °C) wear appropriatePPE! Avoid any skin contact! If hydraulic oil gets into the eyes, rinse carefully with waterand consult a physician!

2 Clean the area round the venting filter.

3 Thoroughly clean the area around the filler and screw plugs on the transport and storagecontainers.

4 Unscrew the venting filter lock and remove the complete venting filter from the pipe socket.

Fire hazard! No smoking! Make sure that there are no flammable liquids, open flame, etc.nearby!

Environmental hazard! In case of leaking hydraulic oil follow the legal provisions andregulations without fail!

5 Empty the hydraulic tank by means of a pump unit via the pipe socket. The suction hosemust 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 andmust be dimensioned to be able to hold the hydraulic oil volume (see "Technical Data"section).

HC6GB0RAHC6DE0RA


Operation

6 Place the venting filter on the pipe socket again.

7 Remove the tank cover and clean the hydraulic tank

8 Remove the housing of the hydraulic filter. Dispose of the liquid in a suitable container, seechapter "Maintenance", "Hydraulic filter" paragraph.

When storing and disposing of hydraulic oils and used oil the local laws and regulationsare to be followed without fail. The proprietor of the machine is responsible for properwaste disposal!

When disposing of the oil pan and cloths drenched with hydraulic oil the laws andregulations applicable must be followed without fail. The proprietor of the machine isresponsible for proper waste disposal!

Operation


7.11.4 Emptying the cooling water supply

If the cooling system is not relieved of all pressure before work starts, there is a risk ofexplosive emptying with possible damage or injury!

Burning hazard if touched! At water temperatures above 50 °C (50,00 °C) wear appropriatePPE!

1 Cut off the water supply to the oil cooler

2 Cut off the water supply (1) to the cooling water flow control.

3 Turn the two hand-wheels (2+3) of the cooling water flow control counterclockwise (Closecooling water flow).

4 Disconnect the cooling water supply and return lines from the oil cooler

5 Drain the cooling water from the supply and return lines of the oil cooler to appropriatesystems or containers

6 Disconnect the cooling water return (4) from the cooling water flow control and drain thecooling water to appropriate systems or containers.

7 Disconnect the cooling water flow (1) from the cooling water flow control and drain thecooling water to appropriate systems or containers.

8 Turn both hand-wheels (2+3) of the cooling water flow control cw (Open cooling water flow)and drain the cooling water to appropriate systems or containers

9 Disconnect the cooling water flow and return (5+6) of the users and drain the cooling waterto appropriate systems or containers

10 Connect the compressed air hose to the supply lines of the oil cooler and the coolingwater flow control and blow out with compressed air.

11 Drain the remaining cooling water from the supply and return lines to appropriate systemsor containers

12 Insert plugs into the fittings of the supply and return lines to protect them againstcontamination

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2356

HC6GB0RAHC6DE0RA


Operation

7.11.5 Evacuating the compressed air system

If the compressed air system is not relieved of all pressure before work starts, there is a riskof explosive emptying with possible damage or injury!

1 Cut off the compressed air supply to the air supply unit.

2 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 suitablecontainer; turn condensate drain screw clockwise.

7.11.6 Other measures1 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 allunpainted, unplated bolts must be preserved using an oily rust preventing agent.

12

3

Operation


7.11.7 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 powerterminals.

3 Secure the supply lines against interference according to locally applicable regulations.

4 Place desiccant medium for protection of connecting terminals, relays, etc. from corrosioninto the electrical cabinet.

7.12 Measures after an extended shutdown1 Clean the machine from dust and rust preventing agent, see chapter "Transport -

Installation".

2 Note the service life of the hydraulic hoses and hose assemblies, see chapter"Maintenance".

3 To prevent the hydraulic pump(s) from being damaged, check whether they are filled withhydraulic oil; see chapter "Transport - Installation".

4 Replace the "Hydraulic filter" and "Venting filter" filter elements; see chapter"Maintenance".

The isolation value may only be checked and moist windings may only be dried by aqualified electrician. The safety regulations in the chapter "Safety" are to be followedwithout 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 withmaterial"

HC6GB0RAHC6DE0RA


Operation

9 Maintain hydraulic system

After extended shutdown, in particular, if there are extreme climatic conditions, themovement of some hydraulic components (e.g. valves) may be restricted due to gummingor precipitations within the hydraulic oil. For this reason the machine should be carefullyrestarted at low set values for the movement speeds and pressures. Carefully observewhether all hydraulic functions have been carried out and the proper function of themachine is ensured.

If necessary, the machine should be filled and flushed out with a cleaning oil (HLPDaccording to DIN 51524 Part 2, Class ISO VG 32). These are hydraulic oils with cleaningadditives (identifying letter "D" = "detergents").

After successful flushing, the machine should be refilled and used with the standardhydraulic oil (HLP 46).

10 Follow the procedures in the respective operating manuals without fail before restarting theperipheral equipment.

Operation


7.13 Changing the place of installation1 Prepare the machine as described in "Shut down procedure".

2 Move the injection unit to its foremost position (into the nozzle platen) before changing theplace of installation

3 Move the clamping platen to the "Mould open" position and adjust the maximum mouldmounting height.

4 Open the clamping unit’s safety gates on the operator’s side and the rear and secure by arope, 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 appropriatelifting 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 ropessuitable 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 theappropriate load.

10 Unload, install, level and commission the machine at the new installation site as describedin chapter "Transport - Installation"

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Operation

7.14 Disposal

The proprietor is obliged to dispose of all components, lubricants, hydraulic and gear oilas well as other aids (cleaning cloths, cleaning agents, etc.) according national andinternational laws and regulations.

This applies especially to those components which have been in contact with productshazardous to the environment (lubricants, hydraulic and gear oils).

Please contact the responsible authorities before disposal. You will receive detailed informationon laws and regulations applicable, the facilities for disposal as well as on authorised wastedisposal companies.

Ask your lubricant supplier for the safety data sheets according to DIN 52900 for the productsthey 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 CatalogueRegulation"). This regulation is to translate the provisions of the decision 94/3/EC on a wastedisposal directory according to Article 1, section a of the Directive of the Council 75/442/EEC onwastes into the German legislation.

In the Directive of the Council 75/442/EEC measures on the avoidance, recycling and thedisposal of wastes are described in Article 3; Article 4 contains the compliance with the principleof non-hazardous waste recycling and disposal. Article 5 stipulates the principles of the nearestpossible and self-reliant waste disposal.

Maintenance

EP6GB0SAEP6DE0SA0510WT Chapter 8 - 1

8 Maintenance

8.1 GeneralCareful installation and proper care are indispensable to ensure the reliable function of the injection moulding machine.

Daily visual inspections help prevent downtimes. Carry out regular inspections and maintenance and replace worn parts. Only use parts of the same quality (strength, material properties) and design as the original parts.

Malfunctions and faults caused by inadequate or improper maintenance can lead to high repair costs and long downtimes of the machine. Regular maintenance is therefore imperative.

If you have any queries regarding the servicing or maintenance of the machine, please contact our technical customer service or one of our agents. For addresses, see chapter „Customer service“.

Always strictly adhere to the safety instructions in chapter „Safety“!Before carrying out any maintenance tasks, shut down the machine at the main switch and secure it against inadvertent switching on!

8.2 Transport, storage and disposal of lubricants

Lubricants and hydraulic fl uids are hazardous substances that can cause damage to the environment. Therefore strictly observe the application statutory regulations for the handling and disposal of such substances, including the regulations in the water protection, construction, waste disposal, transport, processing and occupational safety regulations.

These regulations cover all issues in connection with the transport, storage and disposal of these substances.

However, even strict compliance with these regulations cannot fully eliminate the risk of accidents with lubricants. In the event of such an incident, immediately notify the relevant authorities (environmental protection / police / fi re brigade). The duty of notifi cation of the authorities depends on the amount of spilt lubricant.

The operator must take preventive measures to prevent oil spillage. Such measures include for example an oil incident plan, the storage of suffi cient quantities of oil-binding agents, regular checks of the seals of the sewage inlets and the provision of suitable tools and equipment to prevent the the oil from reaching critical areas.

EP6GB0SAEP6DE0SA

0510WTChapter 8 - 2

Maintenance

Request the relevant material safety data sheets according to DIN 52900 from your oil supplier.

They contain information on the product, including:

• Chemical composition and physical properties

• Protective measures, storage and handling instructions

• Measures to be taken in the event of accidents and fi re

8.3 Disposal of electrical and electronic components

Dispose of all electrical and electronic components according to the statutory regulations.

8.4 Hydraulic fl uid and lubricant table

CAUTIONThe test run of the machine at the factory is always carried out with oil containing zinc. IT is however possible to operate the machine with an equivalent zinc-free oil. The residual quantity of oil in the system upon delivery is approx. 5%, and there are no concerns on the part of the oil supplier as regards mixing with the new oil.

This list is based on the recommendations made to us by the mineral oil companies. It is however possible to use equivalent products from other suppliers, provided that their specifi cations match those of the products listed here.

Maintenance


Only only pre-fi ltered hydraulic fl uid of cleanliness class 17/15/12 according to ISO 4406!

*) Hydraulic fl uid: Use only fl uid of cleanliness class 15/12 according to ISO 4406 after pre-fi ltration!

**) Air-cooled three-phase motors only

Lubrication point

Hydraulic equipment*)

Gearbox, axial bearing and oil

lubrication

Central oil lubrication

Central lubri-cation grease

and grease

Three-phase motor & electric

motors**)

Pneumatics & electromagnetic

couplingDesignation to

DIN 51502HLP 46

DIN 51524 T2CLP 220

DIN 51517 T3CG 220

DIN 51517 T3K 2/3 R - 40DIN 51825

HLO 10 / CL 10DIN 51524 T1

AgipOSO 46

AgipBlasia 220

Agip ASP 220Agip Exidia 220 - Agip

ACER 10

Aral VitamGF 46

Aral DegolBG 220

Aral DeganitB220 - Aral Vitam

DE 10

AVIA FLUIDRSL 46

AVIA GEARRSX 220

Slideway oilRSU 220 - AVIA FLUID

RL 10-C

BP EnergolHLP-HM 46

BP EnergolGR-XP 220

BP Maccurat220 D - BP Energol

HLP-HM 10

Castrol HyspinAWS 46

Castrol AlphaSP 220

MagnaglideD 220 SLX Grease Castrol Hyspin

AWS 10

NUTO H 45 SPARTANEP219

FEBISK 219 - SPINESSO 9

HYDRAN TS 46 GIRAN 220 HYDRAN G220 Pluton EM CIRKAN 10

MobilDTE 25

Mobilgear630

Mobil VactraOil No. 4 - Mobil Velocite

Oil No. 6

RENOLIN B 15VG 46

RENOLIN CLP220/220 Plus

RENEPCGLP 220 - RENOLIN B 3

VG 10

Q8Haydn 46

Q8Goya 220

Q8Wagner 220 - Q8

Haydn 10

Shell Tellus 46 Shell Omala 220

Shell Tonna S 220

Aero Shell Grease 16 Shell Morlina

StraburagsNBU8EP

EP6GB0SAEP6DE0SA

0510WTChapter 8 - 4

Maintenance

8.5 Maintenance schedule

Every 8 operating hours

• Check that all safety devices (1) and all safety covers (2) and guards (including mechanical closing guard) are properly mounted.

• Visually inspect the machine for damage.

• Replace defective indicator lamps (3) without delay.

• Check that the switch cabinet door (4) is kept closed at all times.

• Check the switch cabinet for dirt and clean it, if necessary.

412 12

3

Maintenance



• Check the fi lter pad(s) of the fan in the switch cabinet and the machine frame for contamination.

• Check all hydraulic fi ttings, hose lines, cylinders, valves, pumps, etc for leakage or damage.

• Check the air-conditioning devices (condensate tank, fi lter), if installed.

• Check the fi lling level of the central lubrication pump (STRABURAG NBU 8 EP) (1) and the oil lubrication pump (2).

• Check the various spindles (injection side, clamping side) for oil fi lm. The spindles must be covered around their outer diameters and along the coupling races with a thin fi lm of lubricant!

• Check the grease (3) and oil lubrication lines (4) for damage and proper fi lling with lubricant.

12

Spindle at clamping side

Spindle at injection side

4

3Filling level

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0510WTChapter 8 - 6

Maintenance

6

5

• Check the oil level in the hydraulic tank (5), the injection drive and the metering drive (6). Check the metering and injection drives for leakage and damaged shaft seals.

Maintenance



• Treat all bare metal parts (beams (1), piston rods (1)), that are not moving along other components with a corrosion protection spray.

CAUTION: Do not spray the crosshead guide (3).

• Apply grease to the grease lubrication points of the clamping plate support (4), the drive guide at the injection side (6) and the injection side guide (7) (linear guide).

3

1

3

467

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0510WTChapter 8 - 8

Maintenance

• Remove escaping grease.

CAUTION: Do not lubricate the scraper of the thread roller screw drives (8).

• Complete a functional check of the stop bar of the mechanical closing guard (optional).

• Clean the fi lter cartridge of the air purifi er unit (optional).

• Check the leakage bottle for the toggle lever oil in the machine frame and empty it, if necessary!

9

8

Maintenance



• Check whether the operating manual is in place and complete.

• Check the heating bands for correct position and proper fi t.

• Retighten all terminals in the switch cabinet.

• Check all cables for damage.

• Replace the fi lter pad(s) of the fans in the switch cabinet and the machine frame.

• Clean the switch cabinet.

• Test the emergency-stop circuit.

1

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Maintenance

2

• Check the screw coupling (2) and tighten the screws, if necessary.

• Lubricate the grease lubrication points of the height adjusting unit (3).

3 3

3

3

Maintenance



• Check the stroke transducer for the ejector (1) and the ejector for the nozzle movement (2) for dirt.

• Visually inspect the electrical components.

• Check the nozzle for wear and proper centring.

• Test the hydraulic oil quality (change oil, if necessary).

To determine the local operating conditions to adjust the change interval, test the hydraulic oil at shorter intervals (e.g. monthly) during the initial operating phase.

1

2

EP6GB0SAEP6DE0SA


Maintenance

• Change the fi lter cartridge of the hydraulic fi lter (3).

• Check all screw connections and fi ttings for proper tightness and retighten, if necessary.

• Check the insulation resistance and the protective conductor system.

• Lubricate the axial bearing of the clamping motor (4) with STRABURAG NBU 8 EP.

3

4

Maintenance



• Change the gear oil of the injection and metering drive (1).


• Check the coupling stars (1) of the metering and injection motor; Clean the motor ventilation system of the clamping (2), metering and injection motor (3) with dry compressed air. If necessary, adjust the cleaning intervals to the actual site conditions.

1

1

1

3

2

Oil fi lling volume for gear130 h 5,1 l (1,35 us gal.)

130 speed + 350 h 6,2 l (1,64 us gal.)350 speed + 750 h 9,3 l (2,46 us gal.)

EP6GB0SAEP6DE0SA


Maintenance

• Replace the hydraulic hose lines.

• Flush the oil cooler (optional) and the cooling water fl ow controller (4) with a descaling agent.

4

Maintenance


8.6 Hydraulic system

All work on the hydraulic system must be carried out by a specialist hydraulic technician!If the hydraulic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

Shut off the machine at the main switch and secure the switch with a padlock against inadvertent switching on. The hydraulic system is depressurised, if the clamping plate, the nozzle and the screw are in one of their end positions. To release any residual pressure, carefully loosen (but not open) one of the hydraulic screw fi ttings.

8.6.1 Oil change

Risk of injury from burns! At oil temperatures above 60 °C (140 °F), wear suitable protective clothing!

Dispose of the spent oil according to the statutory regulations. It is the responsibility of the machine operator to dispose of the oil in a safe manner!

Every 5000 operating hours, have an oil sample analysed and change the oil, if this is indicated by the analysis result. To protect the oil, do not exceed the maximum oil temperature of 60 °C (140 °F) and regularly replace the fi lter. To determine the local operating conditions for the adjustment of the change interval, test the hydraulic oil at shorter intervals (e.g. monthly) during the initial operating phase.

The sample must be taken from the pressure line at operating temperature.

The hydraulic oil must be changed every 12 months, irrespective of the operating hours. If the oil is not changed at the appropriate interval, there is an increased risk of malfunction and downtime, due to abrasive particles that have not been removed by the fi lters.

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Maintenance

CAUTIONEscaping leak oil is always contaminated and must not be returned to the hydraulic tank!

Always observe utmost cleanliness! Carefully clean the fi lling nozzle on the hydraulic tank and the fi ller screws and caps at the transport and storage container for hydraulic oil. Check the hydraulic oil for contamination with water. Hydraulic oil contaminated with water is of low quality and must not be re-used!

The oil must be changed immediately after a production run of the machine is completed. This ensures that the oil is at the normal operating temperature (45 °C to 50 °C / 113 °F to 122 °F) and fl ows easily. Also, at this point, the contaminants in the oil are still suspended in the oil so that they can be easily pumped off.

1 Clean the fi ller screws and caps of the transport and storage containers of the hydraulic oil.

2 Test the quality of the hydraulic oil in the storage container; see section „Oil quality“.

3 Filter the hydraulic oil in a mobile fi lter unit (preliminary fi ltration).

4 Switch off the hydraulic system („Hydraulic Stop“ button).

5 Shut down the machine at the main switch and secure it against inadvertent switching on.

6 Clean the area around the breather fi lter.

7 Remove the breather fi lter cap and pull the entire breather fi lter from the pipe piece.

8 Empty the hydraulic tank with a pump unit through the pipe piece. The hose used for this procedure must thereby reach the bottom of the hydraulic tank.

9 Remove the tank lid and clean the hydraulic tank.

CAUTIONIf the maximum fi lling level is exceeded, hydraulic oil escapes through the breather fi lter!

Always add the new hydraulic oil through the air fi lter nozzle. This must be done with a separate fi lter unit (fi lter size 3 μm / 118.11 μinch), which ensures that the oil meets the requirements of cleanliness class 15/12 according to ISO 4406 (class 6 according to NAS 1638 or CETOP RP 70 H). Experience shows that even new hydraulic liquids do not meet these standards.

CAUTIONOnly use new hydraulic oil and never mix oils of different qualities or brands! Unless you have good reasons to do so, do not change the oil type orbrand. If you must change the oil product, fi rst complete a fl ushing run with the new hydraulic oil!

Maintenance


To ensure that oil products are not confused, we recommend marking the oil tank and the fi lling nozzle accordingly.

1 Using a mobile fi lter unit, fi ll the hydraulic tank to the maximum mark.

The maximum mark is the upper mark in the oil level indicator.

2 Mount the breather fi lter on the pipe piece.

3 If required, reconnect the connections of the bypass fi lter unit.

CAUTIONBefore switching on the machine, allow the hydraulic oil to settle for about 1 hour so that all air bubbles can escape!

8.6.2 Bleeding the systemAfter the hydraulic tank has been fi lled, you must bleed the hydraulic system.

• Start the hydraulic drive with the „Hydraulic Start“ button.

• Press the „Setup“ button.

• Move the injection unit and ejector several times back and fore across the entire stroke length.

The system is properly bled, if no oil foam is visible in the hydraulic tank, all movements are performed smoothly and there are no unusual machine noises.

After bleeding, check the oil level and add oil, if necessary. Only add oil of the same grade.

8.6.3 Checking the oil levelThe oil level must be checked constantly (at least once a day) to prevent that the oil level drops below the minimum mark. This would result in an increased operating temperature and the collection of undissolved air in the system, leading to pump failures and cavitations.

8.6.4 Return fi lter

The return fi lter is equipped with a contamination sensor. If this sensor is triggered, an error message is displayed on the screen of the control unit.

Change the fi lter cartridge (prod. no. MB628) at the next available opportunity (break in production run, e.g. at the end of a shift). If no fi lter cartridges are available in stock reorder them as soon as possible.

As a rule, always change the fi lter cartridge each time the oil is changed. If it is necessary to change the oil prior to the next change interval (e.g. due to an error message or a negative oil analysis), also replace the fi lter cartridge.

Utmost cleanliness is essential. The contamination sensor includes a cold start disabler, which means that the respective switch is disabled at oil temperatures below 27 °C (80.6 °F).

EP6GB0SAEP6DE0SA


Maintenance

8.6.5 Changing the fi lter cartridge

• Switch off the IMM and wait until the system is completely depressurised.


Risk of injury from burns! At oil temperatures above 60 °C (140 °F), wear suitable protective clothing!

• Unscrew the fi lter cap (3).

• Pull the fi lter cartridge (1) with the fi lter pot (4), holding it by the bracket.

• Remove the fi lter cartridge (1). Examine the surface for dirt particles. Such particles might indicate that components are damaged.

• Dispose of the fi lter cartridge (1).

• Before installing the fi lter cartridge, check it again to ensure that its designation corresponds to that of the removed fi lter cartridge.

CAUTIONDo not clean and re-use the fi lter cartridge!

• Remove the fi lter cartridge. The fi lter cartridge cannot be cleaned. Any attempt to clean the fi lter cartridge results in damage to the fi lter material, so that contaminations are not held back by the cartridge.

• Clean the inside of the fi lter pot (4) with a suitable agent (e.g. white spirit, petroleum), ensuring that no dirt is inadvertently moved to the clean side of the system.

• Examine the fi lter for mechanical damage, especially on the sealing faces and the threads. Replace damaged parts. Check the O-rings and replace damaged O-rings.

3

2

1

4

Maintenance


CAUTIONIf damaged parts are not replaced and if the fi lter is not in proper working order, there is a risk of damage to other components of the system and impaired performance!

8.6.6 Breather fi lterThe air fi lters allow for clean air exchange as the oil level in the tank fl uctuates. Check the fi lter at least every 2500 operating hours and replace the fi lter cartridge if necessary. The check interval might need to be shortened, depending on the ambient conditions. All tasks must be carried out with utmost cleanliness.

8.6.7 LeakageInspect the hydraulic system for leaks and eliminate them by sealing the area or retightening the respective fi ttings.

Damaged hydraulic hoses and lines must always be replaced without delay. Also see section „Hose lines“!

The hydraulic fi ttings, hoses, cylinders, valves, pumps, etc. must be checked at least every 160 operating hours.

8.6.8 Oil cooler (optional)Although the oil cooler is a maintenance-free component, we recommend servicing it every 20,000 operating hours.

Dirty water must be fi ltered. Where water is hard, the cooling lines must be regularly descaled.

For details, see section „Water quality“.

EP6GB0SAEP6DE0SA


Maintenance

Length including standpipe ends

8.7 Hose linesAlways adhere to the safety instructions laid down in DIN 20066 parts 4 and 5 and EN 201. The standards contain the regulations for the checking, replacement and storage of hydraulic hose lines.

The operator must ensure that the hose lines are replaced at appropriate intervals, even if there is no visible damage to the hose lines that might impair their safety.

8.7.1 Service lifeEven if hoses are properly stored and not exposed to excessive stress, they are subject to ageing. This means that their service life is limited.

Improper storage, mechanical damage and excessive stress are among the most common causes of hose failures.

Do not exceed the service life (including storage time) for hoses and hose lines. Each hose and hose line is marked with the date of production.

Hose lines must be replaced at least every 20,000 operating hours.

Hoses, that have been used in the machine must not be re-used, as they do not meet the requirements laid down in DIN 20066.

If hoses are re-used, the person remounting them will be personally responsible for any subsequent damage.

Use only hose lines with a integrated sealing head. The lengths of the hose lines must be calculated according to the fi gure below.

Maintenance


8.7.2 Inspection criteriaEvery 1000 operating hours, have a specialist hydraulic technician carry out a functional test of the system.

Hose lines where one of the following defects have been detected during the inspection must be replaced without delay:

• Damage to the outer layer and the insert (e.g. chafe marks, cracks, cuts, etc.).

• Embrittlement of outer layer (cracks in hose material).

• Deformations when pressurised or not pressurised, bent sections, separated layers and bubbles (see also DIN 20066, part 4).

• Leakage.

• Damage to or deformation of the hose fi ttings (risk of leakage); minor surface defects do not warrant a replacement.

• Loosening of the hose from the fi tting.

• Corrosion of the fi tting that might impair its function or strength.

• Incorrectly installed lines and fi ttings (see DIN 20066, part 4).

• Products whose shelf life or service life has been exceeded.

EP6GB0SAEP6DE0SA


Maintenance

8.8 Hydraulic accessoriesIf the hydraulic system of the machine has been equipped with additional components (e.g. bypass fi lter unit) at the request of the customer, the operator must read the relevant operating manuals included in the technical documentation, chapter „Accessories“.


Before operating the machine, read the safety instructions and operating manual for the hydraulic unit!

The hydraulic unit must be installed, dismantled, confi gured, commissioned and serviced by authorised specialist technicians!

8.9 Water system

CAUTIONTo protect the water lines, observe the corrosion properties of metal components when exposed to water laid down in DIN 50930!

Water lines and water fi ttings must be inspected weekly by a specialist technician for corrosion and leakage.

If the cooling water system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!

Risk of injury from burns! At water temperatures above 50° C (122° F), wear suitable protective clothing!

Maintenance


8.9.1 Water quality

If the quality of the water at your site deviates from the guide values below, please contact our technical customers service or one of our agents. For addresses, see chapter „Customer service“.

pH: 6.5 - 9

Water hardness: < 1.8 mmol / l (681 ppm / gal)

Suspended particles: < 0.03 ‰ (30 ppm)

Filter mesh size: < 100 μm (0.004")

As regards suspended particles and water hardness, please note that the concentration of suspended particles must be reduced the harder the cooling water. If the concentration of suspended particles is above 0.03 ‰ (30 ppm), install a water fi lter with a fi lter mesh size of < 100 μm (0.004") in front of the water system.

8.9.2 Closed cooling water circuitWe recommend adding a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel).

Recommended anti-freeze agent: ethylene glycol type 420 (60 % water, 40 % ethylene glycol). This additive is suitable for temperatures to -30 °C (-22 °F) and also serves as a corrosion inhibitor.

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Maintenance

8.9.3 Hydraulic oil temperatureCheck the temperature of the hydraulic oil in the oil tank daily. For optimum effi ciency of the machine, the oil temperature should be between 45 °C and 50 °C (113 °F and 122 °F).

8.9.4 Oil coolerFlush the cooling coils every 20,000 operating hours (at max. 16 bar / 232 psi) with a descaling agent to remove any lime scale deposits.

8.9.5 Cooling water fl ow controller• Check the cooling water fl ow controller daily for proper fl ow and leakage.

• Also check the cooling water connections and hoses for unrestricted fl ow (no kinked hoses) and leakage.

• Clean the pipes depending on the degree of contamination of the fl ow medium.

• The consumers, moulds, cooling system of the screw retraction zone, etc. must be fl ushed every 20,000 operating hours with a descaling agent.

Maintenance


8.10 Electrical system

For all work in connection with the assembly, dismantling, relocation and maintenance of the machine, always strictly adhere to the statutory regulations and the instructions in chapter „Safety“!All work on the electrical components must be carried out by a qualifi ed electrician!

8.10.1 Filter padsThe fi lter pads can be cleaned as follows:

• Rinse under water (temperature not higher than 40 °C / 104 °F; if required, use a fi ne washing powder). Alternatively, clean by tapping, blowing out with compressed air or with a vacuum cleaner.

• If the fi lter pads are contaminated with greasy or oily dust, clean them with water and a grease-removing agent.

8.10.2 Buffer batteryTo prevent loss of data, the control unit is equipped with a buffer battery. If error message „Buffer battery empty“ is displayed on the screen, replace the buffer battery. Replace the battery for the fi rst time after 5 years, and then every 3 years.

Battery change (type: 3V/950mA lithium battery):

CAUTIONOperating without buffer battery results in the loss of data! Before changing the battery, take a backup of the service and mould data on a fl oppy disk.

1 Switch off the main switch.

To prevent the loss of data, the battery must be replaced and the main switch must be switched on again within 30 seconds!

2 Ensure that all electrostatic charge is removed from the top-hat rail and the earth connector (do not reach into the power adapter).

3 Open the battery compartment with a screwdriver. To do this, place the screwdriver in the slot and lift off the cover.

4 Pull the battery from the holder by pulling the battery compartment cover.

EP6GB0SAEP6DE0SA


Maintenance

5 Remove the lithium battery (do not touch the battery with pliers or uninsulated pincers -> short circuit). Touch the battery only at the front side. Alternatively, use insulated pincers to remove the battery.

6 Insert the new battery, observing the polarity. Ensure that the removal strip is located below the battery as it is otherwise not possible to remove the battery at a later stage.

7 Close the lithium battery compartment cover.


Dispose of the spent battery according to the statutory regulations. It is the responsibility of the machine operator to dispose of the battery in a safe manner!

Maintenance



If the pneumatic system is not depressurised prior to starting work on the unit, there is a serious risk of injury and damage to the equipment as it might explode!


The secondary fi lter (3)of the UNIFEED material feed unit (optional) must be checked at least once a week and cleaned, if necessary. If the machine is operated in a dusty environment, check the fi lter more frequently. The fi lter has a limited service life and should therefore be replaced immediately if there are any signs of fi bre separation (to remove the fi lter, simply slide it from the guide).

The primary fi lter (2) is cleaned automatically with compressed air after each feed cycle. In the event of excessive contamination, clean the fi lter as follows:

1 Switch off the compressed air system.

2 Remove the knurled nuts (4).

3 Lift off the cover (1).

4 Clean the primary fi lter (2) and reinsert it.

5 Replace the cover.

6 Tighten the knurled nuts (4).

When installing the fi lter, ensure that the O-ring is correctly placed in its position.

1234

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Maintenance

8.11.2 Air purifi er unit Check the oil level in the air purifi er unit (optional) every 8 operating hours and add oil, if required. For the correct oil quality, refer to the „Hydraulic fl uid and lubricant table“.

8.11.3 Filter cartridgeThe cleaning interval for the cartridge is determined by the purity of the ambient air. We recommend cleaning the cartridge every 500 operating hours.

• Switch off the compressed air system.

• Screw out the fi lter cartridge.

8.11.4 Mechanical closing guardThe mechanical closing guard (optional) can only work properly, if all of its components are in proper working order and parts can move freely. Please note that the stop surface against which the tooth of the stop bar is pressed when in locking position is exposed to wear. Prevent malfunction of the mechanical closing guard by regularly turning and replacing the turning plate.

Spares / Plans

HC4GB0TAHC4DE0TA017WT1 Chapter 9 - 1

9 Spares / Plans

The chapter Spares / Plans contains parts list, plans and drawings representing the completerange of the machine, broken down into assemblies. There is an assembly drawing for every sub-assembly. Each spare part can be found here listed under a position number.

In order to avoid misunderstandings, it is necessary to give the Machine Number with every spareparts order. In addition please state the Identification number (ID No.), the Designation and thedesired Quantity.

When ordering, please contact the BATTENFELD agency responsible for you or contactBATTENFELD direct.

HC4GB0TAHC4DE0TA

017WT1Chapter 9 - 2

Spares / Plans

Special descriptions

HC4GB0UAHC4DE0UA017WT1 Chapter 10 - 1

10 Special descriptions

HC4GB0UAHC4DE0UA


Special descriptions

Customer Service

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ServiceWittmann Battenfeld Spritzgießtechnik bietet seinen Kunden ein umfangreiches und effizientesServiceportfolio an. Schnell, zuverlässig und kompetent betreuen die Servicestellen unsereKunden in mehr als 80 Ländern der Welt.

Servicevereinbarungen

1 Präventiv-Service

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3 Voll-Service

Vorbeugende Instandhaltung

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• Zertifizierung für DIN ISO 9000 durch Herstellerdokumentation

Ersatzteilvertrieb

Wenn Sie Ersatzteile für Wittmann Battenfeld Spritzgießmaschinen oder dieAutomatisierungstechnik benötigen, steht Ihnen unser Ersatzteilvertrieb für die Beratung, Prüfungder Verfügbarkeit der benötigten Teile und für die termingerechte Lieferung zur Verfügung.

Unterstützung vor Ort

Je nach Ihren Aufgabenstellungen beraten wir Sie auch gerne in Ihrem Unternehmen, um mitIhnen gemeinsam direkt an den Maschinen entsprechende Optimierungen vorzunehmen.

Wir bieten weiterhin verfahrenstechnische Beratung bei der Prozessoptimierung:

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Plastifiziereinheiten• Plastifiziereinheiten zu fertig entwickelten Verfahrenslösungen

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Service-Hotline

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Schulungen

In unseren Seminaren vermitteln wir ein umfassendes Verständnis der komplexenZusammenhänge im Spritzgießprozess.

Diese Ausbildung ist die Grundlage, um auf die Herausforderungen der Praxis rasch undzielgerichtet reagieren zu können.

Für Ihr Unternehmen bedeutet dies die Wahrung technologischen und anwendungstechnischenVorsprungs.

Unsere Schulungen bieten:

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