product line smartpower b6

O P E R AT I N G I N S T R U C T I O N S

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

PRODUCT LINE SmartPower B6

SM1GBV00 0115

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

Subject to technical changes without prior notice.

We shall not accept any liability for damage caused by printing errors.

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

SmartPower

xxx / xxxx

UNILOG B6x

135xxx-100

2014

SM1GBV00_0115

14.01.2015

SM1GBI2A0115TW Index - 1

1.................................................................................................................Preface

1.1.......................................................................................................................................................... Introduction1.2..............................................................................................................................................Area of Applicability1.3........................................................................................................................................ Explanation of symbols1.4..............................................................................................................................................................Copyright1.5...................................................................................................................................... Certifi cate of Conformity1.6.......................................................................................................................................Commissioning protocol

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............................................................................................................................................. General information3.2............................................................................................................................................ Hydraulic equipment3.3.............................................................................................................................................Electrical equipment3.4....................................................................................................................................................... Water system3.5.........................................................................................................................................................Pump output3.6......................................................................................................................................................... Injection unit.................................................................................................................................................... SmartPower 25/35.................................................................................................................................................... SmartPower 50/60.................................................................................................................................................... SmartPower 80/90.................................................................................................................................................SmartPower 110/1203.7....................................................................................................................................................... Clamping unit.................................................................................................................................................. SmartPower 25 / 35.................................................................................................................................................... SmartPower 50/60.................................................................................................................................................. SmartPower 80 / 90.................................................................................................................................................SmartPower 110/1203.8................................................................................................................................................ Mould dimensions3.9........................................................................................................................Conversion table for shot weights3.10...........................................................................................................................Weights of screws and barrels 3.11 .....................................................................................................................................Torque settings for bolts3.12.................................................................... Torque settings for the fastening screws of the screw barrel head3.13................................................................................................................................................................ Layout

SM1GBI2A0115TWIndex - 2

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

4.1............................................................................................................................................. General information4.2............................................................................................................................................. Unpacking / storage4.3.............................................................................................................................................................Unloading4.4.......................................................................................................................................Space requirement plan4.5.................................................................................................................................... Transporting the machine4.6........................................................................................................................................... Erecting the machine4.7...........................................................................................................................................Transportation device4.8............................................................................................................................ Removing preservative agents4.9.......................................................................................................................................... Levelling the machine4.10................................................................................................................................................Hydraulic system4.10.1...............................................................................................................................................................Filling................................................................................................................................................ SmartPower 25 - 1204.10.2............................................................................................................ Commissioning of the hydraulic pump4.10.3...................................................................................................................................................... Deaeration4.10.4.............................................................................................................................................. Pressure vessel4.10.5........................................................................................................................................Bypass fi ltration unit4.10.6......................................................................................................................................... Core puller (option) 4.11 ..................................................................................................................................................... Water system4.11.1 ................................................................................................................................................... Water quality4.11.2 ................................................................................................................................Cooling water connection4.11.3 ........................................................................................................................... Cooling water fl ow governor 4.11.4 ....................................................................................................................................................... Oil cooling4.11.5 ................................................................................................................................. Temperature control unit4.12..............................................................................................................................................Pneumatic system4.12.1................................................................................................................................................. Air supply unit4.13...........................................................................................................................................Electrical equipment

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

5.1 ......................................................................................................................................................... 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..........................................................................................Structure and function

6.1....................................................................................................................................................... Clamping unit6.1.1.........................................................................................................................................Technical description6.1.2............................................................................................................................................ Mechanical scotch6.2......................................................................................................................................................... Injection unit 6.2.1.........................................................................................................................................Technical description 6.2.2....................................................................................................................................................... Screw drive6.2.3...............................................................................................................................Adjusting the nozzle centre6.2.4.......................................................................................................Basic requirement for changing the nozzle6.2.4.1...............................................................................................................................Changing "open” nozzles


6.2.4.2............................................................................................................................................ Nozzle changing6.2.4.2.1.......................................... Replacing the "Herzog" needle shut-off nozzle of type SHP, spring-controlled6.2.4.2.2.......................................................................................Changing the "Fuchslocher” needle valve nozzle 6.2.4.2.3.............................. Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, ................................................................................................................... type HP, with integrated control cylinder6.2.4.2.4............................................................ Replacing the pneumatically triggered "Herzog” bolt valve nozzle, ................................................................................................................... type HP, with integrated control cylinder 6.2.4.2.5............... Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP 6.2.4.2.6....................... Replacing the pneumatically or hydraulically triggered "Fuchslocher" needle valve nozzle 6.2.4.2.7........................................................ ENG pneumatic needle valve nozzle with integrated control cylinder6.2.5................................................................................................................ Dismantling the screw barrel / screw6.2.5.1 ........................................................................................................... Dismantling the screw up to size 7506.2.5.2 ................................................................................................. Dismantling the screw barrel up to size 7506.2.5.3 ................................................................................Retooling for a different screw diameter up to size 750 6.2.5.4.............................................................................................................................. Dismantling the screw tip6.2.6.............................................................................................................. Cleaning the barrel, material changes6.2.7................................................................................................................. Purging out with virgin polyethylene6.2.8........................................................................................................... Purging out with a barrel purging agent.6.2.9................................................................................................................................. Cleaning the screw barrel6.2.10........................................................................................................................................................... Storage6.3............................................................................................................................................................ Hydraulics6.3.1.......................................................................................................................................... General information6.3.2..........................................................................................................................................................Pump unit6.3.3................................................................................................................................................... Hydraulic tank6.3.4....................................................................................................................................................Pressure fi lter6.3.5...........................................................................................................................................................Oil cooler6.3.6........................................................................................................................................... Control and display6.3.7................................................................................................................................................ Pressure setting6.3.8.................................................................................................................................................... Speed setting6.3.9.................................................................................................................................... Hydraulic oil preheating6.3.10....................................................................................................................................... Hydraulic core puller6.4.......................................................................................................................................................... Pneumatics6.4.1....................................................................................................................................... Pneumatic core puller6.4.2................................................................................................................................................... Air supply unit6.5...............................................................................................................................................................Airmould6.6............................................................................................................................................................... Electrics6.6.1..................................................................................................................................................... Electric drive6.6.1.1........................................................................................................................Speed-controlled servo motor6.6.2...................................................................................................................................................Switch cabinet6.6.2.1................................................................................................................Switch cabinet layout Main cabinet6.6.2.2..................................................................................................................Switch cabinet layout Base frame6.6.2.2........................................................................................................................Switch cabinet layout Heating6.7.............................................................................................................................................. UNILOG B6 control6.7.1.......................................................................................................................................... General information6.7.2.................................................................................................................................................. Operator panel6.7.3................................................................................................................................. Explanation of the picture6.7.4................................................................................................................................................Saving / Printing 6.7.5..........................................................................................................................................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

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

8.1...................................................................................................................................................... Miscellaneous8.2...................................................................................................... Transport, storage and disposal of lubricants8.3................................................................................................ Disposal of electrical and electronic components8.4........................................................................................................................... Hydraulic oil and lubricant table8.5............................................................................................................................................... Maintenance chart8.6..................................................................................................................................................Hydraulic system8.6.1.........................................................................................................................................................Oil change 8.6.2........................................................................................................................................................ Deaeration8.6.3........................................................................................................................................ Checking the oil level8.6.4................................................................................................................................... Oil change Axial bearing 8.6.5................................................................................................................................................... Hydraulic fi lter 8.6.6............................................................................................................................... Changing the fi lter element8.6.7...................................................................................................................................................... Venting fi lter8.6.8................................................................................................................................................................ Leaks8.6.9 ..........................................................................................................................................................Oil cooler8.7................................................................................................................................................... Pressure vessel8.7.1........................................................................................................................ Checking the nitrogen pressure8.7.2................................................................................Replenishing, reducing and testing the nitrogen pressure8.7.3 ......................................................................................................................Checking the hydraulic pressure8.8..................................................................................................................................................Hose assemblies8.8.1........................................................................................................................................................ Service life8.8.2.............................................................................................................................................. Inspection criteria8.9.......................................................................................................................................... Hydraulic accessories8.10......................................................................................................................................................... Lubrication8.10.1...............................................................................................................................Manual grease lubrication 8.10.2..........................................................................................................................................Three phase motor8.10.3..................................................................................................................................................... Screw drive8.10.4........................................................................................................................................Corrosion protection


8.11 ..................................................................................................................................................... Water system8.11.1 .................................................................................................................................................. Water quality8.11.2 ..........................................................................................................................Closed cooling circuit system8.11.3 ................................................................................................................................ Hydraulic oil temperature8.11.4 .........................................................................................................................................................Oil cooler8.11.5 ........................................................................................................................... Cooling water fl ow governor8.12...........................................................................................................................................Electrical equipment8.12.1....................................................................................................................................................... Filter mats8.12.2...................................................................................................................................................Buffer battery8.13..............................................................................................................................................Pneumatic system8.13.1............................................................................................................................... UNIFEED material feeder8.13.2................................................................................................................................................. Air supply unit 8.13.3................................................................................................................................................. Filter cartridge8.13.4.......................................................................................................................................... Mechanical scotch

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

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

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

EWAGB0AC0115TW Chapter 1 - 1

1 Preface

1.1 IntroductionThe operating manual contains information which is deemed to support the user in his work and information which must be adhered to in order to guarantee a safe handling.

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

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

Should you still encounter diffi culties, please contact our Customer Service Department or our Local Technician or Agent (addresses are given in chapter "Customer Service") who will be pleased to help.

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

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

Liability / WarrantyWittmann Battenfeld GmbH assumes no liability for property damage and human injury and/or environmental damage resulting from partial or full non-compliance with the operating manual.

The warranty becomes invalid if unauthorised persons intervene in the equipment.

In the case of personal injury, property damage or damage to the environment, claims by reason of liability or warranty shall be excluded if the damage can be attributed to at least one of the following causes:

• If the damage and/or failure can be traced back to the usage of spare parts other than original spare parts.

• Incorrect operation, insuffi cient maintenance or insuffi cient repair of the components.

• Operation of the components with incorrectly attached, defective or non-functional safety and protective devices.

• Non-compliance with the operating manual for operation, maintenance and repair.

• Changes made to the components without the express approval of Wittmann Battenfeld GmbH. The attachment or removal of components is particularly prohibited.

• Damage due to foreign bodies or force majeure.

EWAGB0AC0115TWChapter 1 - 2

Please observe the operating manualKnowledge of the contents of the technical documentation for the components is a precondition for protecting the employees from danger, preventing errors and for operating the components in a fl awless and safe manner.

• Everyone entrusted with the transport, assembly, initial start-up, operation, maintenance or repair of the components must be knowledgeable of the operating manual. We recommend that the operating company require its operating personnel to confi rm in writing that they are familiar with the contents of the operating manual.

• All requirements and instructions in the operating manual must be complied with.

• All applicable national regulations, regulations for accident prevention and environmental protection and the confi rmed technical requirements for safe and proper work must be complied with.

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

Any other use is regarded as improper. The manufacturer accepts no responsibility for any resulting damage - the risk is borne entirely by the operating company.

ATTENTIONFor test purposes, the injection unit was operated with the following material:Polystyrene STYROLUTION PS 454N (HIPS) processing temperature 180°-260 °C/356°-500 °FIf required, rinse screw barrel with a suitable cleaning material.

EWAGB0AC0115TW Chapter 1 - 3

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

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

The "Hot surface" sign indicates areas where there is a burning hazard. The operating and maintenance personnel must be protected by appropriate personal protective equipment.

Areas indicated by the "Pinch hazard" sign warn of possible pinching or crushing hazards.

Surfaces marked with the "No step" symbol must not be stood on!

ATTENTIONCaution marks those sections with these operating manual where there are instructions or regulations which must be observed and/or that the correct sequence of work should be followed, and / or that care must be taken to avoid damage to the machine and associated equipment.

The High voltage symbol indicates in the manual those places where personnel can come into contact with electrical equipment and materials. Care must be taken to ensure that the applicable local electrical safety regulations are followed.

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

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

EWAGB0AC0115TWChapter 1 - 4

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

1.4 CopyrightThe copyright of this operating manual remains with Battenfeld GmbH. This operating manual is intended for assembly, operating and supervisory staff. It contains instructions and diagrams of a technical nature which may not be reproduced entirely or in part, distributed or used without authorisation for the purposes of competition or conveyed to third parties.

1.5 Certifi cate of ConformityThe Certifi cate of Conformity is included at the end of this Section.

1.6 Commissioning protocol(For internal use only)

EWAGB0BB0414MC Chapter 2 - 1

2 Safety

2.1 Safety regulations 2.1.1 General information

Numerous safety devices on the machine contribute to safety and accident prevention. The proprietor is responsible for the effi cient operation of the safety devices.

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

For safety reasons the control software may not be modifi ed. Any unauthorised modifi cation to the software will invalidate possible claims of guarantee / warranty.

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

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

If the machine, without knowledge of the manufacturer, is installed in a pit or surrounded with a pedestal, the proprietor is obliged to adhere to the safety regulations according to the European Standard EN 201, and especially to EN ISO 13857.

Unauthorised modifi cations and alterations which affect the safety of the machine are not allowed.

Modifi cations and alterations which affect the safety of the machine as well as all work relating to maintenance are to be documented in an inspection record which is to be stored for at least ten years.

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

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

EWAGB0BB0414MCChapter 2 - 2

The machine is designed and built to the currently valid standard EN ISO 12100 so that the noise hazard during proper use and with optimum settings is reduced to the lowest practicable level.

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

Before operating the machine with integrated peripheral equipment (e.g. material feeder) the safety regulations in the appropriate Peripheral Equipment Operating Manual(s) must be followed without fail.

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

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

The installation of a mould-lifting crane from Wittmann Battenfeld GmbH may only be carried out by an authorised skilled technician. The crane may only be used for installing and removing moulds. It is forbidden to linger under the suspended load. The Safe Working Load is shown on the crane's specifi cation plate.

Even if the machine is only subject to slight modifi cations in terms of position it should be disconnected from any power supply. Reconnect all power supplies according to the operating manual before restarting the machine.

If the machine is disposed of to a third party or fi rm, these operating instructions must be handed over with it. If is recommended to have written confi rmation of this.


2.1.2 InstallationFor installation, dismantling, modifi cation, adaptation, and maintenance, work parts, components or the entire machine have to be secured and carefully attached to the lifting gear so as to prevent any dangers from arising. Only use appropriate lifting gear in proper working order with suffi cient carrying force. Personnel or other persons must by no means stand or work under suspended loads.

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

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

After electrical installation or maintenance all the applicable safety measures (e.g protective-conductor system, voltage test, insulation test) must be tested according to the European standard EN60204-chpt20.

Hazards may arise from this machine during setting if the setting is carried out by untrained personnel improperly or for an unsuitable purpose.

Therefore, all setting work may be carried out by a tool setter only.

Tool setters are persons who due to specialised training and experience have suffi cient knowledge of material, moulds and the control of the machine and who are familiar with the relevant safety regulations, regulations for the prevention of accidents, directives and generally approved rules in technology, e.g. DIN standards.


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

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

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

Before putting into operation after repair it must be verifi ed that all the safety devices are in place according to regulations.

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

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

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

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

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

Cleaning materials are classed as fl ammable liquids, hazardous to health. The manufacturers' instructions are to be followed without fail. Do not use aggressive cleaning agents. Use non-fi brous cleaning cloths.

When using oils, greases or other chemical substances, follow the safety regulations applicable to this product.

The proprietor is responsible for secure and proper waste disposal of process material.

Screw connections which have become loose during operating and maintenance work must always be tightened as specifi ed on the table. Check pipework for leaks, loosened screw connections, chafe marks, and damage. Remedy detected defects immediately.


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 fi rst read and understand the appropriate operating instructions, especially chapter "Safety". The proprietor is advised to have this confi rmed in writing.

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

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

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

Responsibilities for installation, dismantling, commissioning, operation, and maintenance must be clearly defi ned and adhered to so that no grey areas arise on the subject of responsibilities for safety.

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

All energy supply lines to the machines (e.g. compressed air, pressurised fl uids, ...) must be switched off.

When undertaking work involving installation, dismantling, modifi cation, operation and maintenance, no fl ammable liquid may be allowed to come into contact with components whose high temperatures could cause a fi re and explosion risk.

Let the following components cool down to a safe temperature before carry out any work involving installation, dismantling, modifi cation and maintenance:

• Heating elements and their guardings.

• Temperature control units, their fi ttings, fl ow and return lines and their mounting elements.

• The outside cooling of the screw barrel (option) and / or the barrel throat zone (option), operated with water or heat transfer oil, including all fi ttings, fl ow and return lines and mounting elements.

• The internal cooling of the screw (option), operated with water or heat transfer oil, including all fi ttings, fl ow and return lines and mounting elements.

The operator must protect him / herself from burning hazards from the heating elements, temperatur control units and their covers, fi ttings, fl ow and return lines and their mounting elements, and the housings of electrical motors by wearing appropriate PPE.


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

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

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

The operator and other personnel may only stand in front of the machine on the operator’s side during operation.

It is forbidden to stand on the machine or to reach into the injection unit during operation.

The shut down procedures given in the operating manual are always to be followed for all work on the machine.

The operator is obliged to report at once any alteration in the machine which affects safety. If necessary, the machine should be switched off at once by operating the emergency stop devices and the main switch.

The operator has a duty always to operate the machine in a fault free condition.

Cleanliness and tidiness of the machine are to be ensured by appropriate instruction and monitoring on the part of the proprietors.

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

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

The operator has a duty to ensure that no foreign bodies enter the material hopper, stuffi ng device, or screw opening.

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

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

The proprietor is obliged to attach corresponding safety labels to moulds (not included in the scope of Wittmann Battenfeld GmbH of delivery) which are equipped with mould nozzles. These safety labels must instruct the operator to use the appropriate personal protective equipment for all work involving installation, dismantling, modifi cations and maintenance of mould nozzles (Hot runner nozzle, Mouldmaster nozzles).

When undertaking work involving installation, dismantling, modifi cation, and maintenance of mould nozzles (Hot runner nozzles, Mouldmaster nozzles), the operator is obliged to wear appropriate personal protective equipment (protection for hands and face, etc.) (EN 407, EN 420, EN ISO 13732, EN 168).


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

In any work involving operation, installation, dismantling, modifi cation and maintenance, the following potential pinching or crushing hazards may arise:

• Between the safety door and safety door frame on closing the clamping unit's safety door(s).

• Between the purge guard and the nozzle platen on closing the purge guard.

• With power-operated shut-off nozzles from the movement of their closing mechanism.

• Between the nozzle and the nozzle platen when moving the injection unit forward with the purge guard open.

• In the area of the screw shaft and thrust bearing (axial bearing) when coupling the screw.

• Around the material outlet when swinging the material hopper in and out or sliding it backward and forwards.

Machine with pedestal:

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

Machines with extended tiebars (with toggle only):

• When setting the mounting height of the mould between guarding and clamping cylinder.

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

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

• Falling mouldings.

There is a cutting and shearing hazard at the edge of the fi lling opening of the hopper when fi lling in the melt.

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

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

• Magnetic fi elds, which, when in immediate proximity, may infl uence sensitive devices such as cardiac pacemakers, hearing aids, disks, etc.

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


2.1.5 Safety regulations Hydraulics / pneumaticsThe machine is designed and built to the currently applicable safety requirements of European Standard EN 4413+ EN 4414 and is safe in operation. Hazards can, however, arise from the hydraulic system of this machine if it is improperly used by untrained personnel or is used for purposes for which it is not designed. For this reasons all work involving installation, dismantling, modifi cations and maintenance may only be carried out by a skilled hydraulic and / or pneumatic technician.

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

Before opening hydraulic and / or pneumatic components and hoses, the hydraulic or pneumatic systems have to be relieved from pressure as described in this operating manual.

Compressed air piping for the pneumatic system and water pipework for the cooling of the hydraulic unit have to be expertly installed and laid. Fittings, length and cross section have to meet the requirements.

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

All pipework, hoses and screw connections should be checked for leaks and damage visible from outside at regular intervals. Remedy damage immediately. Hydraulic oil escaping at high pressure can cause severe injuries and fi res.

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

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

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

Only hose assemblies with fi ttings that were either supplied or specifi ed by Wittmann Battenfeld GmbH should be implemented.

All work involving installation,dismantling, modifi cations and maintenance of pressure vessels may only be carried out by personnel trained in this fi eld.


Work (repair, connection of a pressure gauge) on a machine with pressure vessels must not be carried out until the hydraulic pressure has been released; i.e. the pressure in the pressure vessels must have decayed completely. No welding or machining may be undertaken.

The pressure vessels must be tested at their place of use by the technical standards organisation responsible in the proprietor's region before being put into operation.

Pressure vessels may only be fi lled with nitrogen "N2". The use of other gases causes explosion hazards.

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

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

When disposing of used oil and lubricants the local laws and regulations are to be followed without fail. The proprietor is responsible for proper waste disposal.


2.1.6 Safety regulations for the Modular Airmould® SystemThe Modular Airmould® System (option) has been designed and built to the currently applicable European Standard EN ISO 12100, EN 60204, Part 1, and EN ISO 4414 and is safe to operate. Hazards may still arise from the Modular Airmould® System if it is operated by untrained personnel improperly or for an unsuitable purpose. For this reason, all work involving installation, dismantling, modifi cations and maintenance may only be carried out by personnel trained in this fi eld.

The Modular Airmould® System must be relieved from pressure according to the descriptions in the operating manual for all work involving installation, dismantling, modifi cations and maintenance.

Only those hose assemblies may be used which meet at least the requirements of DIN EN 853 (Type 2SN) whereas the outer layer must be permeable to nitrogen. The safety regulations according to DIN 20066 and EN 201 must also be followed.

Only hose assemblies with fi ttings that were either supplied or specifi ed by Wittmann Battenfeld GmbH should be implemented.

Only hose assemblies with fi ttings which comply with or exceed DIN ISO 12151-2 may be used.

Hose assemblies must be mounted so that:

• Their natural position and movement are not hindered.

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

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

Never paint hose assemblies.

Hose assemblies must not be bent to a tighter bending radius than the minimum specifi ed by the manufacturer.

Torque settings of the union nut must be reached at 1 to 1 1/2 turns of the union nut.

To ensure the proper serviceability of hose assemblies they must be assembled according to DIN 20066.

After fi tting or renewal, hose assemblies must be secured so that any hazard on bursting or blowing off is prevented.

After fi tting or replacing hose assemblies, the serviceability is to be checked by a trained and skilled technician.


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).

The screw connection parts must meet the minimum requirements of DIN 2353, EN ISO 8434-1 "Solderless pipe connections with cutting ring" (Heavy Series S).

Pipe fi ttings must be designed to DIN 3859-1.


2.1.7 Safety regulations for moulding compoundsThe machine is intended exclusively for the processing of moulding compound as stated in the chapter "General information". Any other use is considered improper and any loss damage or injury arising is the responsibility of the proprietor. The manufacturer can accept no liability.

It is the operator's duty to ensure that no drawn in material or explosive air mixtures may be near the heating of the screw barrel or the internal cooling of the screw barrel (option) and the inlet area of the radial fans (option) for the outside cooling of the screw barrel.

The operator has to make sure that the radial fans may only be used in a technically faultless condition and with undamaged electrics.

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

Some moulding compounds, if they are not properly dried, may spit material from the nozzle. Follow the moulding compound manufacturers' instructions.

It is the operator's duty to ensure that the heating of the shut-off nozzle will be reduced before shutting the machine down. Gases are formed if certain types of moulded compounds remain for a longer period of time in out of operation heated shut-off nozzle. These gases can escape explosively through the discharge bore of the shut-off nozzle.

There is a burning hazard at operating temperature from:

• Barrel nozzles, mould nozzles.

• Plasticised moulding compound emerging from the nozzle.

Wear appropriate personal protective equipment.


2.1.8 Safety regulations for electricsThe electrical equipment on the machine is designed and built to the currently valid standards DIN EN 60204-1 and EN 61000-6-4, EN 61000-6-2 and is safe to operate. Hazards can, however, arise from the electrical system of this machine if it is improperly used by untrained personnel or is used for purposes for which it is not designed. Thus all work involving installation, dismantling, modifi cation and maintenance may only be carried out by a qualifi ed electrician (as defi ned in DIN VDE 0105, EN 50110 or DIN EN 60204-1).

The electrical equipment may only be connected to a mains supply which corresponds in terms of current type, voltage and frequency to the specifi cations on the machine's electrical plate. The electrical supply lines must meet the requirements.

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

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

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

For reasons of safety, the operator must log off from the control unit after fi nishing the setting mode in order to prevent unauthorised persons from data entry.

At the end of installation work, for safety reasons, the keys should be removed from all key-operated switches and kept in a safe place.

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

Danger by current impact! At sockets with this specifi cation plate no portable hand-held electrical appliances (e.g. hand drill) may be attached.

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

Not for hand-held electrical appliances suitably!

No FI-protective circuit!GB


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

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

When installing a complete injection unit, only parts supplied or specifi ed by Wittmann Battenfeld GmbH may be used.

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

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

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

Whilst moving the injection plunger or nozzle contact cylinder with the injection unit guarding removed, the operator must maintain a safe distance.

Immediately after moving the injection or nozzle contact cylinders with their injection unit guarding removed, the machine must be switched off again and secured against accidental reconnection.

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

When fi tting or removing the nozzle, screw or screw barrel, no tools may be used which could cause damage to these components.


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

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

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

There is therefore a need to make contingency plans for preventive measures in the case of any incident with oil. This includes the existence of such a plan itself, that suffi cient oil absorbing medium is in stock, that drains can be closed off and that tools and materials are available to prevent the spilled oil from escaping.

Request safety specifi cation sheets according to ISO 11014 (safety specifi cation sheet for chemical products) for your products from your lubricant supplier.

These cover:

• Chemical and physical properties.

• Protective measures, storage and handling.

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

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


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 Measures *)

1 Use of unsuitable materials

Overload of the machine; possibly fi re 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, un-certain operating conditions, escape of hot material

Damage to machine components, shortcomings in production

Instructions in the operating manual

3Guardings 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

4 Operating error Loss of machine function Instructions in the operating manual

Case Hazard Consequence Measures *)

1 Electrical supply (voltage, frequency, cable size) No proper functioning Permanent machine damage Instructions in the operating

manual

2 Unsuitable coolant (Water fl ow rate, pressure) Blockage, overheating Permanent machine damage Instructions in the operating

manual

SM1GB0CA0115TW Chapter 3 - 1

3 Technical data

The chapter "Technical data" contains all the technical data required for normal installation, commissioning and operation of the injection moulding machine.

3.1 General informationMachine type / control see cover sheet

Machine No. / year of construction see cover sheet

Machine weight gross / nett see foundation and installation plan

Main dimensions of the IMM see foundation and installation plan

Noise level (DIN EN ISO 3744 46) 72 dB(A)

3.2 Hydraulic equipmentOil temperature min / max (HLP 46) min 35 °C (95 °F); max. 65 °C (149 °F)Oil temperature min / max (HLP 32) min 25 °C (77 °F); max. 55 °C (131 °F)

Oil cooling trigger temperature (HLP 46) 45 °C (113 °F)Oil cooling trigger temperature (HLP 32) 35 °C (95 °F)

Ambient temperature: +15 - +40 °C (+59 - +104°F)

3.3 Electrical equipmentPower, hydraulic pump see foundation and installation plan

Motor voltage see electrical plate

frequency see electrical plate

Screw barrel temperature max. 350 °C (350,00 °C) (option 500 °C, 500,00 °C)

3.4 Water systemOil cooler: Cooling water consumption aprox. 0.5 - 1.5 m3/ h (0.65 -1.96 cu yd)

Cooling water supply max. 22 °C ( 72 °F) NW 1"

Oil cooler amplifi ed: Cooling water consumption aprox. 0.1 - 1.5 m3/ h (0.13 -1.96 cu yd)

Cooling water supply max. 30 °C ( 86 °F) NW 1"

Cooling water distributor:Cooling water supply Ø 3/4", max. 10 bar (max. 145 psi)

Cooling water return Ø 3/4"

SM1GB0CA0115TWChapter 3 - 2

3.5 Pump output

Pump capacity (litres) 35 50 60 80 95

SmartPower 25/60 XSmartPower 25/130 XSmartPower 35/60 XSmartPower 35/130 XSmartPower 50/60 XSmartPower 50/130 XSmartPower 50/210 XSmartPower 50/350 XSmartPower 60/60 XSmartPower 60/130 XSmartPower 60/210 XSmartPower 60/350 XSmartPower 80/130 XSmartPower 80/210 XSmartPower 80/350 XSmartPower 80/525 XSmartPower 90/130 XSmartPower 90/210 XSmartPower 90/350 XSmartPower 90/525 XSmartPower 110/210 XSmartPower 110/350 XSmartPower 110/525 XSmartPower 110/750 XSmartPower 120/210 XSmartPower 120/350 XSmartPower 120/525 XSmartPower 120/750 X

Power kW 7.5 11 15 18.5 22


3.6 Injection unit

SmartPower 25/35

SmartPower 50/60

Injection unit 60 130 210 350

Screw diameter mm 14 18 22 18 22 25 30 25 30 35 30 35 40Screw stroke mm 90 110 125 150 175Screw L/D ratio 20 20 22 22 22Calculated stroke volume cm3 13,9 22,9 34,2 28 41,8 61,4 88,4 73,6 106 144 123 169 220Specifi c injection pressure bar 3.000 2.593 1.736 3.000 2.864 2.218 1.540 2.940 2.042 1.500 2.835 2.083 1.595Max. screw rotational speed min–1 623 398 310 298Max. plastifi cation fl ow (PS) 2) g/s 1,9 6,2 9 4 5,8 10,5 15,4 8,2 12 18,6 11,6 17,9 28,5Screw torque Nm 90 140 231 140 238 357 420 490 621Nozzle stroke / Nozzle force mm/kN 250/47 250/47 250/86 250/86Injection fl ow in the open cm3/s 40,8 67,5 101 40,9 61,1 78,9 114 59,5 85,7 117 74,1 101 132Injection fl ow in the open withadditional pump (option) cm3/s 65,3 108 161 65,5 97,8 126 182 95,2 137 187 111 151 198

Injection fl ow in the open withaccumulator (option) cm3/s 65,3 108 161 77,7 116 150 216 155 223 303 161 218 285

Barrel heating power kW 2,9 5,5 6,3 5,5 6,3 9 10,4 9 10,4 10,4 10,4 10,4 12,9Number of heating zones incl. nozzle 4 4 4 4

2) according to WITTMANN BATTENFELD standard

Injection unit 60 130

Screw diameter mm 14 18 22 18 22 25 30Screw stroke mm 90 110 125Screw L/D ratio 20 20 22Calculated stroke volume cm3 13,9 22,9 34,2 28 41,8 61,4 88,4Specifi c injection pressure bar 3.000 2.593 1.736 3.000 2.864 2.218 1.540Max. screw rotational speed min–1 436 278Max. plastifi cation fl ow (PS) 2) g/s 1,5 4,4 6,4 2,8 4,1 7,5 10,7Screw torque Nm 65 140 231 140 238 357Nozzle stroke / Nozzle force mm/kN 250/47 250/47Injection fl ow in the open cm3/s 28,6 47,3 70,6 28,6 42,8 55,2 79,5Injection fl ow in the open withadditional pump (option) cm3/s 49 81 121 49,1 73,3 94,7 136

Injection fl ow in the open withaccumulator (option) cm3/s 65 108 161 77,7 116 150 216

Barrel heating power kW 2,9 5,5 6,3 5,5 6,3 9 10,4Number of heating zones incl. nozzle 4 4



SmartPower 80/90

SmartPower 110/120


Screw diameter mm 18 22 25 30 25 30 35 30 35 40 35 40 45Screw stroke mm 110 125 150 175 200Screw L/D ratio 20 22 22 22 22Calculated stroke volume cm3 28 41,8 61,4 88,4 73,6 106 144 123 169 220 193 251 318Specifi c injection pressure bar 3.000 2.864 2.218 1.540 2.940 2.042 1.500 2.835 2.083 1.595 2.743 2.100 1.659Max. screw rotational speed min–1 477 372 298 318Max. plastifi cation fl ow (PS) 2) g/s 4,8 6,9 12,6 18,5 9,9 14,4 22,3 11,6 17,9 28,5 19,1 30,4 39,7Screw torque Nm 140 238 357 420 490 621 770Nozzle stroke / Nozzle force mm/kN 250/47 250/86 250/86 350/86Injection fl ow in the open cm3/s 49,1 73,4 94,7 136 71,4 103 140 74,1 101 132 102 133 169Injection fl ow in the open withadditional pump (option) cm3/s 77,7 116 150 216 113 163 222 117 160 209 147 192 243

Injection fl ow in the open withaccumulator (option) cm3/s 77,7 116 150 216 155 223 303 216 294 384 223 292 369

Barrel heating power kW 5,5 6,3 9 10,4 9 10,4 10,4 10,4 10,4 12,9 11,5 14 17,3Number of heating zones incl. nozzle 4 4 4 4



Screw diameter mm 25 30 35 30 35 40 35 40 45 40 45 50Screw stroke mm 150 175 200 225Screw L/D ratio 22 22 22 22Calculated stroke volume cm3 73,6 106 144 123 169 220 193 251 318 283 358 442Specifi c injection pressure bar 2.940 2.042 1.500 2.835 2.083 1.595 2.743 2.100 1.659 2.678 2.116 1.714Max. screw rotational speed min–1 496 397 318 291Max. plastifi cation fl ow (PS) 2) g/s 13,1 19,2 29,7 15,4 23,8 38 19,1 30,4 39,7 27,9 36,3 43,9Screw torque Nm 420 490 621 770 998Nozzle stroke / Nozzle force mm/kN 250/86 250/86 350/86 350/86Injection fl ow in the open cm3/s 95,2 137 187 98,8 134 176 102 133 169 124 157 194Injection fl ow in the open withadditional pump (option) cm3/s 137 197 268 142 193 252 147 192 243 170 215 266

Injection fl ow in the open withaccumulator (option) cm3/s 155 223 303 216 294 384 223 292 369 229 290 357

Barrel heating power kW 9 10,4 10,4 10,4 10,4 12,9 11,5 14 17,3 14 17,3 21,9Number of heating zones incl. nozzle 4 4 4 4 4 5



3.7 Clamping unit

SmartPower 25 / 35

SmartPower 50/60

SmartPower 80 / 90

Clamping unit SmartPower 25 SmartPower 35

Clamping force kN 250 350Distance between tiebars mm x mm 320 x 270Min. mould mounting height mm 200Opening stroke / Opening force mm/kN 350/25Max. platen distance mm 550Ejector stroke / Ejector force mm/kN 100/26,4Dry cycle time1) s-mm 1,6 – 189Max. mould weight 4) kg 500

Min. mould dimensions mm x mm 196 x 196

1) theoretical, according to EUROMAP 6 4) Max. 2/3 on clamping platen


Clamping force kN 500 600Distance between tiebars mm x mm 370 x 320Min. mould mounting height mm 200Opening stroke / Opening force mm/kN 400/34Max. platen distance mm 600Ejector stroke / Ejector force mm/kN 150/26,4Dry cycle time1) s-mm 1,75 – 224Max. mould weight 4) kg/mm 700




Clamping force kN 800 900Distance between tiebars mm x mm 470 x 420Min. mould mounting height mm 225Opening stroke / Opening force mm/kN 475/42Max. platen distance mm 700Ejector stroke / Ejector force mm/kN 150/41,2Dry cycle time1) s-mm 1,9 – 294Max. mould weight 4) kg 900




SmartPower 110/120

Insulating plates, adapter plates with T-slots, magnetic quick action mould mounting systems, etc. will reduce the standard mould mounting height. For the mould mounting dimensions relevant to your IMM please refer to the dimension diagram at the end of this chapter.

3.8 Mould dimensionsMinimum mould dimensions

With the central clamping cylinder and the construction of the moving platens, the Mouldfi x system ensures gentle application and even distribution of clamping force.

These functions can only be fulfi lled if the minimum dimensions of the mould do not fall below a certain minimum, so that "wrap-round" of the mould mounting platens is kept within acceptable limits.

Since the dimensional accuracy of the injection moulded parts, the loading on the mould and the mould’s function especially with complex tooling (multi-plate tools, side actions) are affected by the wrap-round of the mould mounting platens, keeping to these guidelines will ensure that unacceptable overloading of the clamping unit and the mould are avoided.

The minimum mould dimensions specifi ed in the table (clamping unit) should be observed, bearing in mind the required clamping force in respect of mould loading and energy consumption.

Also take care that, with maximum mould weight, 2/3 of the weight is mounted on the clamping platen.

Special attention must be paid to off-centre moulds and to parallelism of the mould and mould parting surfaces. Any defi ciency here can cause deformation of both the mould and the clamping unit, with a very detrimental effect on the service life of sealing and guiding components.


Clamping force kN 1100 1200Distance between tiebars mm x mm 520 x 470Min. mould mounting height mm 250Opening stroke / Opening force mm/kN 550/53Max. platen distance mm 800Ejector stroke / Ejector force mm/kN 150/41,2Dry cycle time1) s-mm 2,1 – 329Max. mould weight 4) kg 1.100




3.9 Conversion table for shot weightsThe maximum shot weights (g / oz) are calculated by multiplying the theoretical shot volume (cm3 / cu inch) by the factors given above. The grey fi elds contain the factors for thermoset plastics.

3.10 Weights of screws and barrels Load requirements for screw barrel including screw when performing a screw and barrel change.

Material Factor Material Factor

ABS 0.88 PP + 40 % Talcum 0.98CA 1.02 PP + 20% GF 0.85

CAB 0.97 PS 0.91PA 0.91 Rigid PVC 1.12PC 0.97 Soft PVC 1.02PE 0.71 SAN 0.88

PMMA 0.94 SB 0.88POM 1.15PP 0.73 PF 1.3

PP + 20% Talcum 0.85 UP 1.6

Injection unit Screw diameter Weight

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

60 - 750

14 0.55 40 8818 0.71 40 8822 0.87 40 8825 0.98 70 15430 1.18 70 15435 1.38 100 22040 1.57 115 24345 1.77 125 27650 1.97 170 375


3.11 Torque settings for bolts

The torque settings are listed in the spare parts list together with the screws showing different settings. These settings must absolutely be kept.

The torques are based on a frictional factor of 0.10 (μm total) for untreated, Molykote lubricated and cadmium electroplated surfaces, but not for slightly oiled ones.

Thread Nominal size Tightening torque AssemblyProperty class 8.8

[NM] [lbf ft]M4 3 2M5 5.5 4M6 9.5 7M8 23 17

M10 42 31M12 72 53M14 114 84M16 174 128M20 340 251M24 580 428M27 855 631

M27x2 900 664M30 1160 856

m33X2 1680 1239m36 2030 1497

m36X" 2200 1623m39 2620 1932m42 3240 2390m48 4890 3607


3.12 Torque settings for the fastening screws of the screw barrel head

These torque settings are valid for socket head cap screws (1) for fastening the nozzle head (2).

Further information on tensile strengths etc. can be found in the spare parts lists.

3.13 Layout

Standard version

Thread Nominal size Tightening torque AssemblyProperty class 12.9

[NM] [lbf ft]M8 35 26M12 130 96M16 300 221M20 550 406M24 1000 738M30 2000 1475

High temperature heater bands

Thread Nominal size Tightening torque AssemblyProperty class GB

[NM] [lbf ft]M8 25 18M12 90 66M16 200 148M20 350 258M24 650 479M30 1280 944

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SM1GB0DA0115TW Chapter 4 - 1

4 Transport - Installation

4.1 General informationAfter delivery of the injection moulding machine, it should be checked immediately for any damage and/or for completeness. If necessary, they must be reported immediately to the transport company. Putting into operation must not take place if a transport damage which will restrict proper operation is assumed.

The machine delivery kit includes:

• Operating instructions

• Levelling mounts (option).

All the keys etc. for the switch cabinet, guarding etc. are to be found attached to the main switch.

We would recommend installation of the machine to be carried out by personnel of the Wittmann Battenfeld GmbH. We can accept no responsibility for damage resulting from improper handling.

The foundation plan and installation plan can be found in the chapter "Technical Data". This chapter includes, amongst other information, the machine weights and dimensions. These must be considered when installing the machine.

The installation drawings have been simplifi ed for clarity.

4.2 Unpacking / storagePlease observe the rules of environmental protection. Ensure that all packing material will be disposed of properly and environmentally friendly.

The machine is packed as standard to withstand transportation without damage. However it should be commissioned immediately after handover from the transport company.

If it is to be stored for a longer period, our customer service department has to be contacted.

4.3 UnloadingTrouble free operation and some clauses of the guarantee are conditional upon proper unloading!The machine may only be lifted and moved horizontally and using the provided lifting and transport elements. It is essential that the lifting gear is prevented from slipping!Only nylon slings of suffi cient length are to be used; other types of lifting gear may damage the tiebars.The safe working load of the crane and the slings must equal or exceed the weight of the machine. See chapter "Technical data", Foundation and installation plan for details!Follow without fail the transport plan fi xed to the machine!

SM1GB0DA0115TWChapter 4 - 2

No persons may stand or linger under the suspended load!The complete machine may only be placed on a level surface capable of supporting the load of the machine.Trouble free operation can not be guaranteed if the complete machine is placed on an uneven fl oor.

If there is no level surface, a foundation must be built for the machine according to the "Foundation and Installation Plan", see "Technical Data" chapter, to provide a level base.

If transport to the fi nal location is impossible with cranes, the machine must be supported under its entire base for moving across the fl oor.

4.4 Space requirement planThe exact space requirement can be taken from the machine layout in the "Technical Data" chapter.

A minimum space of 1.3 m (52 inch) must be allowed around the machine for maintenance work.


4.5 Transporting the machine

This machine is equipped with a transport monitoring system. Please handle this machine according to the transport instructions. Improper handling causes a reaction of the indicator. It is absolutely necessary to state in the transport documents whether the indicator is missing or has reacted.


For installation, dismantling, modifi cation, adaptation, and maintenance, work parts, components or the entire machine have to be secured and carefully attached to the lifting gear so as to prevent any dangers from arising. Only use appropriate lifting gear in proper working order with suffi cient carrying force. Personnel or other persons must by no means stand or work under suspended loads.Loads may only be fastened, secured and transported by experienced, authorised and trained personnel.Before installation of the machine the safety measures detailed in DIN EN 292-2, Para. 6.1.2 must be complied with.If the transport plans do not agree with the following descriptions and diagrams, the transport plans in the "Technical Data" chapter are to be taken as defi nitive!

SmartPower 25-120Fork lift transport

Crane transport with one lifting gear.


Machine weight

SmartPower machine weightTYPE kg lbs

SmartPower 25/60 2500 5513SmartPower 25/130 2500 5513SmartPower 35/60 2500 5513SmartPower 35/130 2500 5513SmartPower 50/60 3000 6615SmartPower 50/130 3000 6615SmartPower 50/210 3100 6836SmartPower 50/350 3100 6836SmartPower 60/60 3000 6615SmartPower 60/130 3000 6615SmartPower 60/210 3100 6836SmartPower 60/350 3100 6836SmartPower 80/130 4000 8820SmartPower 80/210 4100 9041SmartPower 80/350 4100 9041SmartPower 80/525 4200 9261SmartPower 90/130 4000 8820SmartPower 90/210 4100 9041SmartPower 90/350 4100 9041SmartPower 90/525 4200 9261SmartPower 110/210 4500 9923SmartPower 110/350 4500 9923SmartPower 110/525 4600 10143SmartPower 110/750 4600 10143SmartPower 120/210 4500 9923SmartPower 120/350 4500 9923SmartPower 120/525 4600 10143SmartPower 120/750 4600 10143


4.6 Erecting the machineThe injection moulding machine may only be installed in a dry, dust-free environment above freezing point. The machine body must completely rest on the levelling mounts or the wedge elements.

Adjustment of the oscillating elementsAdjustment is made by means of the hexagon bolt. A hexagonal nut (2) is used as a lock nut to fi x the height adjusted by the screw (1).

Type Height Setting range SmartPower 25 - 120

Oscillating element Ø 160/M16 59 mm [2.32 inch] 30 mm [1.18 inch] 8


4.7 Transportation deviceThe transportation devices described in this paragraph must be removed before commissioning the machine and MUST be replaced before the IMM is moved!

SmartPower safety gateThe clamping unit's safety gates on the operator's side and the rear are opened and secured by a rope around the machine frame tied to each handle.


4.8 Removing preservative agents

ATTENTIONAll bare parts are protected with a corrosion inhibitor STALOC Korrotech 3000 SQ1003 to protect the machine. When commissioning the injection moulding machine, it is absolutely necessary that the preservative agents are removed exactly and completely, e.g.: with STALOC SQ200, multi-function oil (WD40, Castrol DWF..), nitro, degreasing agent (brake cleaner). The preservative agent will stick in the guide rails if just one single stroke was made without having removed the preservative agent. Grinding of the guide rails will then be inevitable.

Small components delivered with the IMM such as screw tips and stop rings are protected by wax dipping. The wax coating should be removed before use.

ATTENTIONDo NOT protect the spindle with a preservative agent or remove the corrosion protection! If corrosion protection is required, use the prescribed operation grease.

These cleaning fl uids are considered hazardous to health and are fl ammable. Follow the manufacturers’ instructions!

The local regulations must be observed when disposing of these liquids and cloths soaked in them!

Injection unit 60-750

1 Nozzle contact cylinder piston rods

2 Guide rails Injection unit

3 Hopper base plate

4 Screw barrel, shaft and mounts

1

3

4


Clamping unit 25-120

1 Mould mounting surfaces

2 Ejector coupling and guides

3 Guide rails of the clamping platen

1

2

3


4.9 Levelling the machineA machine spirit level with an accuracy of 0.1 mm / m (0.004 inch / 3.281 ft) and a true straight-edge are essential for levelling the machine. In addition, the machine must be equipped with levelling mounts / wedge elements (option).

The machine level (1) is laid across the clamping unit slideways (2) on the straight-edge (3) and the machine is levelled lengthways and across to 0.2 mm/m (0.008 inch / 3.281 ft) by means of the levelling mounts / wedge elements.

Injection unit

The centricity of the nozzle has been set in the factory, but must still be checked after moving the machine, and readjusted if necessary.

• Fill with hydraulic oil; see "Hydraulic unit".

• Connect power; see "Electrical equipment" paragraph

• Select "Setting" mode.

• Move the injection unit back until the nozzle is fl ush with the near face of the nozzle platen.

• Switch off at the main switch and secure against accidental reconnection.

• Adjusting rules for the nozzle centre see Chapter "Strucuture and Function"

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SM1GB0EA0115TW Chapter 4.10 - 1

4.10 Hydraulic system

Work at the hydraulic system may only be carried out by a skilled hydraulic technician!

If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury!

If the clamping platen, nozzle and screw are not in one of their end positions then the hydraulic system is relieved from pressure. Any residual pressure can be released by carefully loosening (but not completely undoing) a hydraulic screw connection. In case of hydraulic systems with pressure vessels (option) you have to wait until the system has been completely relieved from pressure. See also the paragraph "Checking the hydraulic pressure" in chapter "Maintenance".

Turn off the mains switch and secure it against accidental reconnection.

4.10.1 FillingThe oil fi ller neck (1) is located behind the clamping unit.

CAUTIONThe machine’s hydraulic unit requires oil of the cleanliness class 17/15/12 according to ISO 4406. Contamination above this cleanliness class by improper fi lling or use of unsuitable hydraulic oil will invalidate the guarantee!If hydraulic oil becomes contaminated with water it will be of inferior quality and must not be used any further!

1

SmartPower 25 - 120

SM1GB0EA0115TWChapter 4.10 - 2

The hydraulic tank may only be fi lled with hydraulic oil as detailed in the "Maintenance" chapter. The required volume of oil is detailed in the machine layout (chapter "Technical Data").

CAUTIONTest the hydraulic oil for the possible ingress of water!

Never switch the machine on without hydraulic oil. Even the shortest period of running will damage hydraulic equipment!

When fi lling for the fi rst time the following sequence must be followed without fail:

• Clean the fi ller screws and the screw plugs on transport and storage containers.

• Verify the grade of oil; see "Maintenance" chapter.

• Prefi lter the hydraulic oil through a mobile fi ltration unit with a 3 μm (118.11 μinch) mesh.

• Make sure that the main switch is switched off and secured against accidental reconnection.

• Remove guarding if necessary.

• Clean around the fi ller and venting fi lter.

• Remove the lock of the fi ller and venting fi lter (the fi lter screen must remain in place for fi lling).

Fill the oil tankfor the fi rst time with "clamping side open"

• Fill hydraulic tank to the maximum oil level through a mobile fi ltration unit with 3 μm (118.11 μinch) mesh until the fl oat in the oil sight glass has reached the max. marker. The oil sight glass is located at the clamping side front of the machine.

Fill the oil tank for the fi rst time with "Clamping side open" (e.g. with mounted mould).

• Fill hydraulic tank to the maximum oil level through a mobile fi ltration unit with 3 μm (118.11 μinch) mesh until the fl oat in the oil sight glass is located above the min. marker. The oil sight glass is located at the clamping side front of the machine.

In this situation, never fi ll in oil up to the max. marker.

CAUTIONBefore switching on the machine, the hydraulic oil should be allowed to stand for approx. 1 hour to let the air trapped during fi lling escape!

Sw

itchi

ng le

vel

50 m

m (1

.97

inch

)MIN

MAX

HM_1014.PMP


4.10.2 Commissioning of the hydraulic pump• Activation of the pump rinsing program for pump system 1 and pump system 2 if present

(option).

CAUTIONBefore switching on the hydraulic pump the hydraulic motor’s direction of rotation should be checked!

• Start the machine

• If there is air present in the pump system, e.g. due to a pump or oil change, activate this program to eliminate the air from the system.

• The pump rinsing program is to be activated for 20 minutes approx. The program has to be deactivated afterwards.

• The oil heating starts if the oil operating temperature has not been reached with the pump rinsing program.

• If the clamping unit is in the "open" position, move the clamping unit to the front position (refi ll oil if necessary) and carry out a complete dry cycle (oil is distributed in the system).

• If the clamping unit is in the "closed" position, slowly open the clamping unit and observe the oil sight glass. If the oil level exceeds the visible part of the gauge, oil must be removed to carry out a complete dry cycle (oil is distributed in the system).

• If the oil level is lower than the min. marker after this process and the oil level detector emits an error message, only fi ll in oil until the error message can be acknowledged.

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

UNILOG B6


If the tank is fi lled above the maximum level, hydraulic oil will come out of the venting fi lter! In this case, the suction pipe and the fi lter housing have to be cleaned and the fi lter insert has to be replaced.

• Remount the fi lling and venting fi lter onto the pipe socket.

• Attach guarding if necessary.

4.10.3 DeaerationAfter fi lling the hydraulic tank air must be bled from the hydraulic system.

• Connect power; see "Electrical equipment" paragraph.

• Connect cooling water; see "Water system" paragraph.

• Press the "Hydraulic start" key to switch on the hydraulics.

• Press the "Setting" key.

• Open and close all safety gates.

• Drive the clamping platen, nozzle and screw forward and backward over their whole stroke several times.

Bleeding is carried out effectively when no foam appears in the hydraulic tank, movements are smooth and there are no strange noises.

The oil level should be checked after bleeding and topped up if necessary. Care must be taken to use the same oil type.

Any oil leaks arising after a few operating hours are usually cured simply by tightening the screw connections.

4.10.4 Pressure vesselPressure vessels (option) integrated into the hydraulic system allow increased injection output.

Work on plants with pressure vessels may only be carried out by a specially trained technician!

Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released!

Risk of explosion! Only use nitrogen "N2" as gas!

Before starting up the machine the nitrogen pressure within the pressure vessel must be checked. In case the nitrogen pressure falls short of the indicated value (see name plate), nitrogen has to be refi lled.

Pressure vessels are subject to the safety regulations applicable at the place of use. Before starting up the machine, they have to be accepted by the technical standards organisation (e.g. TÜV) responsible in the proprietor’s region.

The proprietor of pressure vessels is responsible for ensuring the proper condition, operation and monitoring.


Neither welding nor soldering nor any mechanical processing may be performed on the pressure vessels. Improper repairs can cause severe accidents and may only be carried out by authorised customer service personnel.

Replenishing, reducing and testing the nitrogen pressure

CAUTIONThe nitrogen pressure changes temperature dependently. For this reason, inspections should always be carried out under equal temperature conditions. After fi lling or discharging nitrogen please wait 5 minutes approx. until the temperature has been balanced. Check the gas pressure afterwards!During each check nitrogen will escape through the fi lling unit. This will reduce the nitrogen pressure, especially in case of small pressure vessels!

The pressure within the mobile nitrogen cylinder (for fi lling the pressure vessel) may not exceed the maximum permissible operating pressure of the machine’s pressure vessel or the pressure gauge. Otherwise a pressure reducer has to be inserted between the mobile pressure cylinder and the fi ller!Please keep all certifi cates in a safe place!

When demanding certfi cates later on, please state the contents, the factory number and the year of manufacture of the vessel. These data is embossed on both ends of the vessel.

1 Screw a pressure gauge connection-Hose assembly Nominal diameter ND2; G 1/4 (option) to the fi tting of a pressure gauge, 0 to 600 bar / 8700 psi (option), not included in the standard delivery

2 Clean the surroundings of the miniature measuring connection at the hydraulic block of the pressure vessel.

3 Remove the sealing cap of the miniature measuring connection.

4 Screw in the fi tting of the pressure gauge connection-hose assembly.

5 Switch off the machine at the main switch.

6 Wait for the pressure of the hydraulic oil within the pressure vessel to be reduced (until the pressure gauge indicates 0 bar / psi).

7 Unscrew the covering cap(s) of the gas fi lling valve.

1

910

2

87654

1 - Non-return valve (valve insert) 2 - Button 3 - Valve gate 4 - Pressure pin 5 - Venting valve 6 - Union nut 7 - Seal element 8 - Connection piece (SAE 7/8" - 14UNF -2B) 9 - Gas fi lling valve 10 - bubble accumulator

3


8 Screw the fi ller unit to the gas fi lling valve.

9 Check whether the venting valve of the fi ller unit is closed.

10 Screw the hose assembly’s connecting piece to the nitrogen bottle.

11 Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly fl owing into the pressure vessel (for the fi lling pressure please refer to the hydraulic plan or the respective label).

12 Close the shut-off valve after reaching the desired nitrogen pressure.

13 Use the venting valve to close the fi lling hose.

14 Press the button of the fi ller unit, release it and read off the nitrogen pressure at the pressure gauge.

15 In case the nitrogen pressure is too high, carefully press the pressure pin after opening the venting valve to reduce the pressure.

Steps 10, 11 and 12 will be omitted when reducing or checking the pressure.

4.10.5 Bypass fi ltration unitBy using a bypass fi ltration unit the machine’s downtime will be considerably reduced by having longer service and maintenance intervals.

For this purpose connection points on the back of the tank for the return line from the bypass fi ltration unit and the fl ow from the hydraulic tank to the bypass fi ltration unit are provided.

The bypass fi ltration unit must be connected with the hydraulic tank empty if the shut-off valves (option) are not fi tted.

After proper connection of the supply and return lines, the shut-off valves must be opened before the bypass fi ltration unit is started up.

4.10.6 Core puller (option) see Chapter "Strucuture and Function"

Hydraulic core pullers may only be fi tted and put into operation by a hydraulic technician! The safety regulations in the chapter "Safety" are to be followed without fail!

EWAGBFC0115TW Chapter 4.11 - 1

4.11 Water system

ATTENTIONWhen installing water pipework note the corrosion stability of metallic materials against water in accordance with DIN 50930!

4.11.1 Water qualityIf there are deviations from the following guidelines, please contact our technical customer service or one of our subsidiaries. The addresses can be found in the "Customer service" chapter.

• pH value: 6,5 - 9

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

• Solids: < 0.03 ‰ (30 ppm)

• Filter mesh: <100 μm (0.004 mm)

In the relation of solids content to water hardness, it should be noted that the harder the cooling water is the lower the solids content has to be. If the level of suspended matter is over 0.03 ‰ (30 ppm), a water fi lter with a mesh size <100 μm (0.004 inch) must be fi tted before the water system.

It is also recommended to add a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel).

We recommend ethylene glycol type 420 as an antifreeze (60 % water and 40 % ethylene glycol). This is suitable for a temperature range down to -30 °C (-22 °F) and is also a corrosion inhibitor.

4.11.2 Cooling water connection

If the cooling system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury!

The cooling system for the IMM can also be run as a closed cooling system. The purest, most chalk-free water should be used. The required nominal diameters of the hoses are quoted in the chapter "Technical data". The bore of the fl ow and return lines must not be smaller than those of the connections on the IMM.

EWAGBFC0115TWChapter 4.11 - 2

4.11.3 Cooling water fl ow governor The cooling water fl ow governor provide cooling water for various users, such as mould, screw barrel, etc., from a common water supply. The cooling water fl ow rate and thus the temperatures of the various consumers are controlled by the appropriate hand-wheels.

1 Common fl ow to cooling water fl ow governor

2 Common return from cooling water fl ow governor

3 Flow to user

4 Return from user

5 Hand-wheel to control cooling water fl ow to user

6 Hand-wheel to control cooling water return from user

7 Thermometer to show cooling water return temperature

8 Bobbin to show fl ow rate

9 Marker-ring to mark preset fl ow rate

10 Scale for setting

Burning hazard if touched! Wear suitable PPE with water temperatures above 50 °C (122 °F)!

Injury hazard to operating and other personnel and possible damage to cooling water fl ow governor if used at improper temperatures and pressures!

22

7

1

6

5

3

4

4

3

5

1

6

7

10

8

9

EWAGBFC0115TW Chapter 4.11 - 3

The cooling water pressure must be set for different temperatures according to the following table:

• The cooling water hoses must be routed so that unhindered water supply and return are ensured. Kinks and squeezing will prevent the optimised fl ow of the cooling water.

Water assemblies have to be expertly installed and laid. Fittings, length and cross section have to meet the requirements!

• Make sure the hoses are long enough to allow for movement of the various units.

• The hoses must be suitable for the system pressure (max. 10 bar - 145 psi) and the ambient temperatures used (max. 80 °C - 176 °F)

Before the cooling water fl ow governor is connected it must be ensured that the hand-wheels (5 and 6) are closed clockwise.

Next, the various users are connected to the cooling water fl ow governor (3 and 4).

Now the cooling water fl ow governor is connected to the cooling water system (1 and 2). By turning the two hand-wheels (5 and 6) counterclockwise, the cooling water fl ow is opened and the required fl ow rate can be set.

Using the marker ring (9), the required fl ow rate can be marked so that the desired fl ow rate can be set again easily after a user has been turned off.

The fl ow rate set can be calculated from the bobbin's (8) position in the water stream and the scale (10) using the following chart.

Temperature max. pressure

40°C (104°F) 10 bar (145 psi)60°C (140°F) 8 bar (116 psi)80°C (176°F) 6 bar (87 psi)

Flow range per circuit

Brass bobbin 0,5 - 10 l/min (0.11 - 2.20 imp.gal/min)Temperature max. 80°C (176°F)

Pressure max. 10 bar (145 psi)

EWAGBFC0115TWChapter 4.11 - 4

4.11.4 Oil coolingThe hydraulic oil is cooled in a heat exchanger. In which the cooling water is passed through a cooling coil surrounded by the hydraulic oil.

A solenoid valve regulates the water fl ow. By allowing or interrupting the cooling water supply it achieves a constant oil temperature.

A temperature sensor in the hydraulic tank measures and monitors the oil temperature and sends the actual values to the IMM's control unit. This in turn orders the solenoid control valve to be opened or closed.

Water assemblies for cooling the hydraulic system have to be expertly laid and installed. Fittings, length and cross section have to meet the requirements!

• The cooling water hoses must be routed so that unhindered water supply and return are ensured. Kinks and squeezing will prevent the optimised fl ow of the cooling water.

• The hoses must be suitable for the system pressure and the temperatures reached in use.

The optimum effi ciency of the injection moulding machine is at an oil temperature between 45 °C and 50 °C (113 °F and 122 °F) HLP 46, with HLP 32 between 35 °C and 40 °C (95 °F and 104°F). The maximum temperature of the supplied water must not exceed 22 °C, 72 °F, (30 °C, 86°F) with reinforced oil cooler.

4.11.5 Temperature control unitTemperature control units (option) are used for liquid temperature conditioning of moulds, barrels and screws.

Before operating the IMM its Safety regulations and those of the temperature control unit must be observed without fail!

A temperature control unit may only be installed by a qualifi ed electrician (according to DIN VDE 0105, IEC 364 or equivalent)!

The installation, connection and commissioning of the temperature control unit are detailed in the separate Operating Manual and in the corresponding wiring diagram in the "Spare parts / Plans" chapter.

The standard location for the connection(s) is on the side of the switch cabinet.

Cooling water consumption conditions

Oil side max. 16 bar (232 psi)Water side max. 10 bar (145 psi)

Water 2 m/s (1,8 yd/s)Oil-Water 25°C (77°F)

SM1GB0GA0115TW Chapter 4.12 - 1

4.12 Pneumatic system

Compressed air piping for the pneumatic system must be expertly laid and installed. Fittings, length and cross section have to meet the requirements!Work at the pneumatic system may only be carried out by a skilled pneumatic technician!If the compressed air system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury!

4.12.1 Air supply unit

1 Setting knob pressure control valve

2 Condensate separator

3 Pressure gauge

4 Condensate reservoir

5 Drain screw

Turn pressure valve control knob (1) clockwise until the desired pressure (min. 6 bar - max. 10 bar / min. 87 psi - max. 145 psi) is shown on the pressure gauge (3).

1

23

4

5

SM1GB0GA0115TWChapter 4.12 - 2

SM1GB0HA0115TW Chapter 4.13 - 1

4.13 Electrical equipmentThe IMM may only be connected to a power supply which corresponds in phase, voltage and frequency to the data given on the electrical specifi cation plate.

Electrical installation may only be carried out by a qualifi ed electrician (qualifi ed to DIN VDE 0105 or IEC 364 or equivalent)!The electrical supply lines must be designed according to the specifi cations on the name plate!The currently valid local regulations on earthing and overload protection (overload, wrong polarity protection) in TN-, IT- or TT supplies must be observed without fail by the proprietor of the machine!The protection for the phase conductors and the neutral conductor (IT-supply) must be arranged to comply with the data on the electrical specifi cation plate!Connection as "Classical zerorising" (PEN-conductor) must not be used. PE-conductor and N-conductor (if used) must always be connected separately!

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

If the IMM is equipped with two separate power connections, they must not be connected to a joint supply line. Hence there are four connection schemes:

1 - Lead without neutral

2 - Lead with neutral

1T31T2

1T1

4 (L1, L2, L3, PE)

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

1T11T2 N

1T3

SM1GB0HA0115TWChapter 4.13 - 2

3 - Separate leads for drive and heating without neutral

4 - Separate leads for drive and heating with neutral

Checking the direction of rotation of the hydraulic pump’s drive

Before switching on the IMM it must be ensured that:

• The hydraulic system is sealed, the switch cabinet is closed, the hydraulic tank is fi lled and the hydraulic pump(s) has/have been primed.

• The guarding and safety gates have been properly fi tted and are closed.

CAUTIONThe pump will not work correctly if the direction of rotation is wrong and the drive and the hydraulic pump will fail!

• Connect the supplies as described in paragraph "Electrical equipment".

The hydraulic motor’s direction of rotation may only be tested by a qualifi ed electrician!

• Open the electrical cabinet.

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

4 (L1, L2, L3, E)

4 (L1, L2, L3, E)

1T11T2 2T3

2T22T1

1T3

1T11T2

N2T3

2T22T1

1T3

4 (L1, L2, L3, E)

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

SM1GB0HA0115TW Chapter 4.13 - 3

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

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

• Switch off the supply voltage (low voltage distribution) if the direction of rotation is not correct and exchange two phases of the power connections 1L1, 1L2, and 1L3 of the mains lead in the switch cabinet.

• Close the switch cabinet.

Finally start the hydraulic pump(s) in "Setting mode" and allow to run for a few seconds without load in order to lubricate the hydraulic pump(s).

SM1GB0HA0115TWChapter 4.13 - 4

SM1GB0IA0115TW 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 latter should be switched off and the supplied dummy plug must be inserted. Operation of the machine without this linking out is not possible. The installation of the links is detailed under "Interfaces".

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

• Mould height and dimensions must suit the machine.

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

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

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

• Check that the water fi ttings are the right size.

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

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

5.2 Mould mounting1 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 "Drive On" key

SM1GB0IA0115TWChapter 5 - 2

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

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

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

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

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

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

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

11 Clamping the mould on the nozzle platen

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

11.2 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 details please refer to the manufacturer of the mould!

11.3 The mould halves must be prevented from sliding apart.

11.4 The mould must hang horizontally from the lifting equipment.

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

11.5 Bring the mould into the open clamping unit.

11.6 Locate the mould in the nozzle platen’s centring hole.

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

CAUTIONThe number of mould clamps must be adapted to the mould weight and the opening force of the machine!

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


The mould clamps (mounting elements for the mould; not supplied as standard with the machine) must be the same height as the thickness of the mould mounting platen, as otherwise there is a risk of the mould slipping.

If necessary use proper washers.

The above points apply equally to the mounting of a mould to mounting platens with T-slots.

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

11.10 For adjusting the zero points of the mould "Zeroising Clamping unit" refer to the chapter "Machine in general / Zeroising".

12 Clamping the mould to the clamping platen

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

The lifting equipment should not be removed until the mould is bolted securely to both platens and this has been verifi ed by an authorised technician!

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

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


13 Set clamping force

13.1 Press the "Manual operation" key.

13.2 Press the "Clamping unit" menu key.

The "Clamping unit" page appears.

13.3 If the input fi eld "Clamping force" is pressed, the "Numpad" appears. Here, the wished clamping force can be entered in "kN" (shtn) (see also User manual A5).

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

CAUTIONIf the machine is to stand idle for an extended period of time, press the "Setting mode" key and close the mould, continue to press the "Close mould" key (rinsing program of the clamping side is activated automatically).

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


14 Log off from the control

CAUTIONTo prevent set value entries by unauthorised persons, the user must log off after fi nishing setting!

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

If you want to interrupt or fi nish your work at the control unit, you will have to logout fi rst.

This procedure prevents unauthorised input at the control unit.

14.2 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".

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

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

16 Connect the mould heating and cooling.

CAUTIONPlease note the correct passage direction since the cooling may otherwise be subject to negative infl uences.The lines and cables must be laid and installed as not to be damaged by the mould or the machine.


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

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

Mould mounting

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

2 Press the "Setting mode" key.

3 Move clamping platen fully back.

4 Move injection unit fully back.

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

5 Switch on key-operated "Mouldfi x" switch (Position 1).

6 Move out (release) the wedge clamping elements of the "Mouldfi x" for the nozzle and the clamping platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the movements of the clamping platen will be disabled.

7 The mould parts must be prevented from sliding apart.

8 Move the mould with the adapter platen of the nozzle unit into the nozzle platen’s "Mouldfi x" until reaching the limit stop.


9 Clamp the nozzle side part of the mould to the nozzle platen by activating the wedge clamping elements of the "Mouldfi x" for the nozzle platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the movements of the clamping platen will be disabled.

10 Move the clamping platen slowly forward until the mould is closed and the clamping unit’s entire adapter platen fi ts to the clamping platen.

11 Clamp the clamping unit’s part of the injection mould to the clamping platen by activating the wedge clamping elements of the "Mouldfi x" for the clamping platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the closing movement will be disabled.

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

13 Switch off key-operated "Mouldfi x" 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 mould mounting platen.


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

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

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

Mould mounting

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

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


4 Move clamping platen fully back.

5 Move injection unit fully back.

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

7 Check whether magnetic modules have been demagnetised.


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

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

CAUTIONThe power of the magnetic modules amounts to up to 16 kg / cm2 (5,58 lb / sq.in.). During magnetising an object between the mould and the magnetic module will be uncontrollably clamped and damaged!

9 Ensure that thereare no magnetisable objects (e.g. spanners) within the clamping unit area.

10 Magnetise the nozzle unit’s magnet mounting plate.

11 Check the clamping procedure; the respective pilot lamp must light up on the control panel or the manual operation unit.

12 Remove lifting gear from mould.

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

14 Magnetise the clamping unit‘s magnet mounting platen.

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

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


5.5 InterfacesThe interfaces and sockets for the peripheral equipment (option) are located on the rear side of the machine.

Details of installation, connection and commissioning are to be found in the appropriate Operating Manuals.

Before operating the machine with peripheral equipment, it is essential that the safety regulations and operating manual of these devices are followed!

Electrical installation may only be carried out by a qualifi ed electrician!

For some peripheral equipment a dummy plug must be used in the interface when the machine is operated without the peripheral equipment.

See also the appropriate wiring diagrams in "Spare parts / plans" chapter.

Before switching on the emergency stop buttons should be released by rotating a quarter turn clockwise and program selection switches set to the required position.

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

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

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

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

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

• Hydraulic interlock: Proper function and securely fi xed limit switch.

• Mechanical scotch (option): Proper function and free movement of swinging scotch (fl ag) on the clamping platen and the correct position (teeth) of the scotch bar.


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

• Purge guard: Proper function, free movement and securely fi xed limit switches.

• Purge guard, safety gate and guarding: Security of all fi xing bolts and undamaged condition and proper function.

5.7 Test run and interlock test

Operating and other personnel may only stand in front of the machine on the operator’s side during operation!It is forbidden to stand on the machine or to reach into the injection unit during operation!Install required safety devices. The safety regulations in the chapter "Safety" are to be followed without fail!

• After electrical installation safety devices are to be tested.

• Check hydraulic lines and components for leaks.

• Check all visible fi ttings for security.

• Close safety gates and check for proper fi tting.

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

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

• Turn on water supply to oil cooler

• Check function of safety devices.

CAUTIONIt is essential to select "Setting" mode, or else the test run may damage the mould!

Check the movements of the various units as follows:

• Switch on main switch (to "1").

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


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

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

• Switch on drive ("Drive On" key).

• Start the pump without load and run it for a few seconds to allow for adequate lubrication.

• Press the "Setting mode" key.

• Assuming that the mould has been left in the "Mould closed" position after mould mounting, open it with the "Mould open" key.

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

SM1GB0JA0115TW Chapter 6 - 1

6 Structure and function

6.1 Clamping unit

6.2 Injection unit

6.3 Hydraulic

6.4 Pneumatics (option)

6.5 Airmould (Option)

6.6 Electric system - main switch cabinet

6.7 Control

6.26.76.1 6.3 6.6

SM1GB0JA0115TWChapter 6 - 2

SM1GB0KA0115TW Chapter 6.1 - 1

6.1 Clamping unit

1 Clamping platen

2 Ejector

3 Nozzle platen

4 Thrust pin

5 Clamping cylinders

6 Quick-action cylinders

7 Tiebars

8 Suction pipe

9 Filling valve

5 2 14 3

6

7

8

9

SM1GB0KA0115TWChapter 6.1 - 2

6.1.1 Technical descriptionThe clamping unit can be considered as an independent assembly attached to the machine frame by bolts in the nozzle platen.

To allow unrestricted extension of the tiebars, the end platen is fl exibly linked to the machine frame.

The clamping force is established by means of the clamping cylinder which is formed as plunger piston.

The clamping force is established by means of an arranged clamping cylinder and transferred to the clamping platen via thrust pins.

Clamping and opening is carried out via two symmetrically arranged double-acting and quick-acting cylinders.

The moveable clamping platen is guided on the machine frame by the clamping platen support.

The standard clamping platen supports consist of linear guide elements which transfer the weight into the machine body. They are preadjusted in the factory and require no further adjustments.

The hydraulic ejector is built into the clamping platen in the form of a double-acting hydraulic cylinder.

6.1.2 Mechanical scotchThe mechanical scotch (option) prevents the closing movement of the moving platen when the safety gate is open.

CAUTIONThe mechanical scotch is an accident prevention device. It can only be effective if all components are in perfect condition and the moving parts operate freely. Care must be taken that the face of the scotch (or "fl ag"), against which a tooth of the scotch-bar presses when it is activated, shows no signifi cant wear. By replacing the scotch in time, malfunctions of the mechanic safety device to prevent closing can be prevented!

SM1GB0LA0115TW Chapter 6.2 - 1

6.2 Injection unit

6.2.1 Technical description

The main components of the injection unit (or carriage) are the screw barrel (1), the nozzle contact cylinder (2), the injection cylinder (3), the drive and bearings (4), hydraulic motor (5), the material hopper and the support.

Low maintenance linear bearings enable precise axial movements of the injection unit.

The mechanical stop prevents any movements out of the linear bearings when dismantling the screw.

The two nozzle contact cylinders are designed as double-acting hydraulic cylinders. The piston rods are designed as guide rails and are attached to the nozzle platen. The nozzle contact cylinders have a long stroke so that the nozzle is easily accessible when the carriage is moved right back.

A stroke transducer, on the rear side of the machine, records the movements of the nozzle contact cylinders and transfers them to the machine control.

The screw is driven directly by a low speed hydraulic motor. This minimises the rotating masses. The torque of the hydraulic motor is suited to the load at any time.

2

1

3

5

4

SM1GB0LA0115TWChapter 6.2 - 2

A proximity switch records the screw speed and transfers it to the control. A stroke transducer, on the rear side of the machine, records the stroke of the screw and transfers it to the machine control.

The injection unit ensures a high plasticising rate, achieved partly by an optimised L/D (= length / diameter) ratio. The barrel and the nozzle are equipped with ceramic heater bands. Different heat outputs and zones can be obtained by arranging of several heater bands side by side.

ATTENTIONTo ensure a long service life for the screw barrel heater bands, they should be checked for secure fi tting when hot at regular intervals, starting with commissioning!

Depending on the moulding compound to be processed, the heating of the screw barrel is additionally equipped with an outside cooling (option) by means of radial fans or with a cooling by means of heat transfer oil (option).

The material hopper which is used for receiving the moulding compound can be easily removed by undoing one fi xing bolt. The hopper outlet can be closed with a slide.

A magnet (option) in the material hopper is used for separating steel particles from the moulding compound. This procedure is recommended especially when processing regranulated material.

Three continuously adjustable brackets allow adjusting the magnet to the desired distance to the wall of the material hopper.


6.2.2 Screw drive

Before checking, the machine must be switched off at the main switch and must be secured against accidental reconnection!

The axial bearing of the injection unit is arranged so that the leakage line from the hydraulic motor lubricates it. No maintenance is thus necessary in this case.

With the servomotor option, the oil level must be checked before the fi rst start-up and, if necessary, oil must be fi lled or refi lled.

For the demands on the lubricant refer to the paragraph "Hydraulic oil and lubricants".Care must be taken to only use gear oils having the same specifi cation.

For the check and oil change intervals, please refer to the "Maintenance" chapter.


6.2.3 Adjusting the nozzle centre

Injection unit up to size 1330

Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment!

1 Measure the centricity of the nozzle with a caliper gauge by measuring the distance from the nozzle bore to the opening in the platen at several places - at least four. The tolerance must not exceed 0.2 mm (0.008 inch).

2 Use the 3 set screws (1) after unscrewing the locking nuts (2) to move the screw barrel into the required position. In this process, always unscrew the "opposite" set screws and tighten after the adjustment to avoid twisting the screw barrel.

3 Retighten locking nut (2) and set screws (1).

4 Then carry out another measurement for test purposes.


6.2.4 Basic requirement for changing the nozzle

1 Press the "Manual operation" key.

2 Set peripheral equipment (option) to the starting position and switch off any peripheral equipment according to its operating manual.

3 Switch off material feeder (option).

( ) Only for Airmould® nozzle: Shut off the nitrogen supply to the Airmould® pressure generation unit.

If appropriate, switch off the Airmould® nitrogen generation unit according to the separate operating instructions.

Switch off the Airmould® pressure generation unit according to the separate operating manual.

If components of the machine are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for installation, dismantling, modifi cation, operation, and maintenance!

Do not use components of the machine as climbing aid. When working at greater heights to proper equipment for protection against falling down must be worn!

4 Move the climbing aid in front of the machine.

5 Move the "Material hopper" away from the "Screw Barrel" feed zone.

6 Move the "Core pullers" (option) out of the mould. "Move out core puller" means that the moulding is removed from the mould or ejected by the "Ejector" if the "Core puller" has been moved into this position.

7 Move the "Clamping platen" to the starting position (mould open).

8 If necessary remove the moulding(s) from the mould using the "Ejector".


9 Heat the "Screw barrel" heating to the operating temperature that was set last.

10 Press the "Injection unit back" key until there is enough room to purge the remaining moulding compound.


11 Open the "Protective guard” of the "Nozzle”.

12 Place a suitable container in front of the "Nozzle".

Risk of injury from pinching or crushing hazard between the purge guard and the nozzle platen when closing the purge guard!

13 Close the "Protective guard" of the "Nozzle".

14 Eject the residual moulding compound at short intervals.

15 Purge the screw barrel with an appropriate cleaning material.

Consult your plastics manufacturer about the suitable material.

16 Switch off water system, pneumatic system, modular Airmould system (option). See also the paragraph "Shutting down the machine" (chapter "Operation").

17 Press the "Injection unit back" key until there is enough space to remove the "Nozzle".

Only for Airmould® nozzle:If the nitrogen system is not relieved from pressure before starting work, it may lead to an explosive loss of pressure with risks of damage and injury!

For Airmould® nozzle:

( ) Relieve the "Modular Airmould® system" from pressure. For the procedure see the operating manual "Modular Airmould® system" (chapter "Transport - installation", paragraph "Preparation for no-load mode and interlock test without material").

( ) Switch off the main switch at the "Modular Airmould® system" and secure against unintentional reconnection.


18 Switch off the heating of "Nozzle" and "Screw barrel".

19 Switch off hydraulics ("Hydraulics stop" key).

20 Switch off the main switch and use a padlock to prevent accidental reconnection. The main switch should be operated whenever possible without applied load.

21 Open the "Protective guard" of the "Nozzle".


The nozzle may only be dismantled and mounted by an authorised skilled technician!If components of the machine are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for installation, dismantling, modifi cation, operation, and maintenance!Do not use components of the machine as climbing aid. When working at greater heights to proper equipment for protection against falling down must be worn!

ATTENTIONOnly use tools and support equipment that will not damage the assembly components!

The remaining procedure is described in the following chapters depending on the nozzle type


6.2.4.1 Changing "open” nozzlesFigure 1 Open nozzle

Figure 2 Open Airmould® nozzle, pressure-controlled

Basic requirement paragraph 1-20 (chapter 6.2.3.1)

1 Dismantle the heater band of the "Nozzle" (1).

2 Position a hexagon spanner on the "Hexagon" (3) and unscrew the "Nozzle" (2).

Only for Airmould® nozzle:

Unscrew the "Union nut" (B) of the "Nitrogen pressure line" (A) at the "Nozzle body".

3 Position a hexagon spanner on the "Hexagon" and unscrew the "Nozzle body".

Fire hazard! Use no fl ammable solvents!

4 Thoroughly clean the "Nozzle" and the "Nozzle body". Use wire brush or brass brush.

Thoroughly remove old grease residues in the thread gaps.

Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.

The components can also be cleaned in an ultrasonic cleaning reactor or a fl uidized bed bath. We also recommend the use of a blast system with thermoset particles.

Danger of injury and damaging components! Only components that were either supplied or specifi ed by Battenfeld should be implemented!

1

2


ATTENTIONDo not use any oily lubricants which may evaporate!

5 Lubricate the thread of the new or cleaned "Nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F).

Check the contact surfaces for damage and wear before mounting.

When fi tting a new "Nozzle" it should be fi rst verifi ed that the "Nozzle radius" is correct for the sprue bush (whose radius should be slightly larger than that of the "Nozzle").

6 Screw the "Nozzle body" home by hand but do not fi nally tighten.

7 Screw the "Nozzle" home by hand but do not fi nally tighten.

8 Mount the heater band of the "Nozzle".

9 Switch on main switch.

10 Switch on hydraulics ("Hydraulics Start" key).

11 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature.


The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl ying out!

12 Tightly screw in the "Nozzle” and "Nozzle body” after heating to operating temperature. Torque settings see chapter "Technical data”.


Screw in the "Union nut" of the "Nitrogen pressure line" at the "Nozzle body" until there is a signifi cant increase in force detectable.


13 Close the "Protective guard” of the "Nozzle”.


Switch on the main switch at the control cabinet of the "Modular Airmould® system".

Pressurize the "Nitrogen pressure line" and check the "Union nut" for leaks. For the procedure see the operating instructions "Modular Airmould® system" (chapter "Maintenance") paragraph "Nitrogen leakages".


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


6.2.4.2 Nozzle changing

Working data Shut-off nozzles

Setting instructions of the external shut-off cylinder pneumatic / hydraulic:

Nozzle closed:

Needle contacts the nozzle point, piston in the shut-off cylinder in fl oating position - minimum distance to unit > 1mm

Nozzle open - Herzog system:

Needle shoulder contacts nozzle body, lever is retracted from the needle, however, does not touch the basic body, piston of the shut-off cylinder in limit position on unit

Nozzle open - Fuchslocher system:

Needle with cross yoke contacts nozzle body, lever will rollers is retracted from the cross yoke > 1 mm, piston of the shut-off cylinder in limit position on unit

Guide values of the lever strokes - setting stroke of shut-off cylinder - see table


6.2.4.2.1 Replacing the "Herzog" needle shut-off nozzle of type SHP, spring-controlled

1 Body

2 Needle guide bush

3 Fixing pin

4 Thrust ring

5 Spring assembly

6 Adaptor

7 Shut-off needle

8 Nozzle head

9 Heater band

10 Temperature probe

6

4

3

2

97

10

8

51



1 If necessary, unscrew "Temperature probe" (10)

2 Dismantle the heater band of the nozzle (9)

3 Screw out the nozzle head (8)

4 Withdraw the shut-off needle (7)

5 Screw off the "Adaptor" (6)


6 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush.





ATTENTIONDo not use any oily lubricants which may evaporate!Do not grease components coming into contact with the melt!

7 Greasing these components will cause impurities to the melt.

Lubricate all threads of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F).

Check the contact surfaces for damage and the individual components for wear and function before mounting.



8 Mount the needle valve nozzle in reverse order

9 Screw the adaptor (6) home by hand but do not fi nally tighten

10 Insert the shut-off needle (7)

11 Screw the nozzle head (8) home by hand but do not fi nally tighten

12 Mount the heater band (9) of the nozzle

13 If necessary, screw the temperature probe (10) home by hand but do not fi nally tighten






17 Tightly screw in the adaptor / head / temperature probe after heating to operating temperature.

Tightening torque: "Nozzle head" (8) - 220 Nm (162 ft lb).

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

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

"Adaptor" (7) - see the "Technical Data" chapter.




6.2.4.2.2 Changing the "Fuchslocher” needle valve nozzle

1 Nozzle body

2 Spring chamber

3 Compression spring

4 Heater band

5 Shut-off needle

6 Nozzle head


1 Screw out the temperature probe

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

3 Position a hexagon spanner on the "Hexagon" and unscrew the nozzle body (1).

The "Spring chamber" (2) must not be dismantled. We can accept no responsibility for damage resulting from improper handling!

If the needle valve nozzle does not function any more, please contact our Customer Service. The addresses can be found in the "Customer service" chapter.

6 52

3 1

4










Lubricate all thread of the new or cleaned "Needle valve nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F).



6 Screw the nozzle body (1) home by hand but do not fi nally tighten.

7 Mount the heater band (4) of the "Nozzle".

8 Screw in the temperature probe.







12 Tightly screw in the "Nozzle" and "Nozzle body" after heating to operating temperature.

Torque setting: Nozzle head (6) - 300 to 350 Nm (221 to 258 ft lb).

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




6.2.4.2.3 Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP, with integrated control cylinder

1 Nozzle head

2 Shut-off needle

3 Fixing pin

4 Lever bolt

5 Lever

6 Screws

7 heater band

8 Temperature probe

9 Adaptor

10 Yoke / adaptor ring

11 Control cylinder

1

2

3

6

7

8

9

54 11

10



1 If necessary, unscrew temperature probe (8).

2 Dismantle the heater band (7) of the nozzle.

3 Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from the control cylinder (11) and remove the lever (5).

4 Screw out the nozzle head (1).

5 Withdraw the shut-off needle (2).

6 Screw off the adaptor (9).







ATTENTIONDo not use any oily lubricants which may evaporate! Do not grease components coming into contact with the melt!






9 Mount the needle valve nozzle in reverse order.

10 Screw the adaptor (9) home by hand but do not fi nally tighten.

11 Insert the shut-off needle (2).

12 Screw the nozzle head (1) home by hand but do not fi nally tighten.

13 Mount the heater band (7) of the nozzle.

14 If necessary, screw the temperature probe (8) home by hand but do not fi nally tighten.

15 If the control cylinder (11) did not reach the wished position after having screwed it in (e.g. control cylinder (11) faxing vertically up), the 12 screws (6) must be screwed out by 4 turns and then the position of the control cylinder (11) can be changed clockwise.

16 Tighten 2 screws (6) crosswise, check the gap between body and adaptor ring up to a

maximum of 2.5 mm (0.1 inch)

1

7

6

Turn clockwise


17 Tighten all screws crosswise

18 Connect pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the control cylinder (12) and mount the lever (5).







Tightening torque:



Torque HP0 HP1 HP2

1st step Prefi xing Prefi xing Prefi xing2nd step 7 Nm 15 Nm 35 Nm3rd step 10 Nm 22 Nm 45 Nm4th step 12 Nm 25 Nm 50 Nm

Designation Torque

HP0 HP1 HP2Screws 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 handTemperature probe by hand by hand by hand


6.2.4.2.4 Replacing the pneumatically triggered "Herzog” bolt valve nozzle, type HP, with integrated control cylinder

1 Nozzle head

2 Bolt lock

3 Lever bolt

4 Lever

5 Screws

6 Heater band

7 Temperature probe

8 Adaptor

9 Yoke / adaptor ring

10 Control cylinder

11 Shut-off nut

12 Body

1

234

5

89

10

7116

12





3 Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from the control cylinder (10) and remove the lever (4).



6 Screw out the shut-off nut (11).

7 Remove the bolt lock (2).

Sometimes, the removal of bolt and bolt bushing might be a problem Do not exercise too much force on this part. If you have problems during removal, please contact the Herzog company.

Use a mandrel to carefully knock up the bolt. Remove bushing and bolt from above.

The grooves on the bolt bushing must be aligned on the body by means of the positioning pin.



8 Thoroughly clean the components of the "Nozzle". Use wire brush or brass brush.










10 Mount the bolte valve nozzle in reverse order.


12 Push in the bolt lock (2) and screw in the shut-off nut (11).




16 Connect pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the control cylinder (10).








Tightening torque: 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).

21 Close the "Protective guard” of the "Nozzle”.



6.2.4.2.5 Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP

1 Adaptor

2 Temperature probe

3 Heater band

4 Nozzle head

5 Screws

6 Rod assembly



2 Dismantle the rod assembly (6).



5 Withdraw the shut-off needle.

















12 Screw the head (1) home by hand but do not fi nally tighten.










Tightening torque:

19 Assemble the rod assembly (6).



Designation Torque

HP0 HP1 HP2Screws 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 handTemperature probe by hand by hand by hand


The nozzle is delivered as sub-assemblies. The fi nal assembly is made on the machine

After having aligned the rod assembly with the nozzle, the fl ange bolts can be tightened crosswise in four steps. The gap between body and adaptor ring can change between 0.5 and2.5 mm (0.02 and 0.1 inch).

Tighten the screws crosswise

Step 1 = prefi x all screws evenly

Step 2 = 70 % of the tightening torque

Step 3 = 90 % of the tightening torque

Step 4 = tighten with 12 Nm (9 ft lb)

Flange bolts

Rod assembly

Gap between body and adaptor ring


6.2.4.2.6 Replacing the pneumatically or hydraulically triggered "Fuchslocher" needle valve nozzle

1 Nozzle body

2 Thrust ring

3 Heater band

4 Nozzle head

5 Shut-off needle

6 Fork


1 If necessary, unscrew temperature probe.

2 Dismantle the heater band (3).

3 Dismantle the rod assembly from the fork (6).


5 Withdraw the shut-off needle (5).

6 Screw out the nozzle body (1).

6

5

4

3

2 1


















14 If necessary, screw the temperature probe home by hand but do not fi nally tighten.





6.2.4.2.7 ENG pneumatic needle valve nozzle with integrated control cylinder

1 Nozzle body

2 Control cylinder

3 Rod assembly

4 Nozzle head

5 Body

6 Tension nut


1 If necessary, unscrew temperature probe.

2 Dismantle the heater band.

3 Dismantle the rod assembly (3).


5 Withdraw the shut-off needle.

6 Screw out the nozzle body (1).

5

4

3

2

1

6















11 Insert the shut-off needle.


13 Mount the heater band of the nozzle.

14 If necessary, screw the temperature probe home by hand but do not fi nally tighten.








Tightening torque: "Tension 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).




6.2.5 Dismantling the screw barrel / screw6.2.5.1 Dismantling the screw up to size 750

1 Dismantle the "Nozzle" as described in the paragraph "Dismantling the nozzle".

2 Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical stop.

3 Open the "Safety gate” on the operator and rear side.



4 Unscrew the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen".

5 Press the "Injection unit forward" key. The "Piston rods" of the "Nozzle contact cylinders" are moved in.




8 Dismantle the cover of the "Guarding" of the "Injection cylinder".

ATTENTIONOnly use tools and aids which do neither damage the nozzle nor its components described below!

9 Slightly unscrew the "Screws" (1) of the "Clamping disc" (2) and remove the two "Wedges" (3).

10 Slightly loosen but do not unscrew the "Clamping bolt".

11 Swivel out the "Injection unit" in the direction of the operator side.

12 Dismantle "Nozzle" and / or "Nozzle head" as described in this chapter.


13 Secure the "Screw" with a corresponding aid and pull it out of the "Screw barrel" to the front. For the weight of the "Screw", see the "Technical data" chapter.

14 If necessary, unscrew the "Screw tip" as described in this chapter.

Danger of injury and damaging components! Only parts (nozzle, screw, barrel and its fi xing screws) supplied or specifi ed by Battenfeld may be used!

15 Clean the "Screw" and the "Screw tip" or mount a new "Screw" and "Screw tip".

- Coat all threads with a temperature resistant Molykote.

- Check the contact surfaces for damage and the individual components for wear and function before mounting.

The "Screw" is always mounted in reverse order as described in this chapter.

6.2.5.2 Dismantling the screw barrel up to size 750

1 Dismantle the "Screw" as described in this chapter.

2 Disconnect the heater band and temperature sensor of the "Screw barrel" at the corresponding plug connection.

3 Disconnect the radial fans for the "Outside cooling of the screw barrel" (option) at the corresponding plug connection.



4 Dismantle the "Guarding" of the "Screw barrel".


ATTENTIONThe "Screw barrel" must not be placed on the "Heater bands" since they can be damaged by its weight.

5 If no appropriate facility for placing the "Screw barrel" is available, the heater bands and the radial fans for the "Outside cooling of the screw barrel" (option) have to be dismantled.

6 Screw in the "Extension" (threaded rod) into the threaded borings in the "Screw barrel".

7 Screw the "Eye bolts" into the "Extension".

Danger of death! It must be ensured that no persons stand or linger beneath the suspended barrel. For weights, see chapter "Technical data"!

The safe working load of the lifting gear must equal or exceed the weight of the screw barrel!Do not use nylon lifting slings. Lifting equipment must withstand the temperature of the screw barrel!

8 Attach the lifting gear to the "Eye bolts" and take up the slack.

9 Unscrew "Bolt".


10 Unscrew the "Locking ring". (Special tool: C-spanner according to DIN 1810)

11 Loosen the "Hexagon nuts" and slightly unscrew the "Screws".

12 Remove the "Screw barrel" forwards from its "Drive coupling". Make sure the lifting equipment is also moved along slowly. For the weight of the "Screw barrel", see the "Technical data" chapter.

13 Place the "Screw barrel" on a suitable facility. The "Screw barrel" must not be placed on the "Heater bands" since they can be damaged by its weight!


Fitting

Before installing the "Screw barrel", the entire mating surface must be coated with a corrosion inhibiting lubricant.

Coat all threads with a temperature resistant Molykote. Check the contact surfaces for damage and the individual components for wear and function before mounting.

Danger of injury and damaging components! Only parts (nozzle, screw, barrel and its fi xing screws) supplied or specifi ed by Battenfeld may be used!

The "Screw barrel" is then installed in reverse order.

ATTENTIONThe torque settings for the "Bolts" are detailed in the chapter "Technical Data" and/or in the spare parts list.

After fi tting the centricity of the nozzle should be checked ("Transport - Installation" chapter).

6.2.5.3 Retooling for a different screw diameter up to size 750


If components of the machine are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for installation, dismantling, modifi cation, operation, and maintenance!Do not use components of the machine as climbing aid. When working at greater heights to proper equipment for protection against falling down must be worn!

Coat all threads with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F). Check the contact surfaces for damage and the individual components for wear and function before mounting.

1 Dismantle "Screw" and "Screw barrel" as described in this chapter.

2 Cover the entire mating surface of the new "Screw barrel" with a "Heat-resistant Molykote".

3 Mount the new "Screw barrel" as described in this chapter.

4 Mount the "Screw tip" as described in this chapter.

5 Insert the new "Screw" into the "Screw barrel" until the "Screw shaft" is located in front of the "Thrust piece".


6 With a "Screw" with a smaller diameter, mount the supplied "Sleeve" onto the "Screw shaft" (push on).

7 Push the "Screw shaft" into the "Thrust piece" to the stop.

8 Adjust the "Screw shaft" so that the "Wedges" can engage in the cut.

9 Insert the new "Wedges" (3) into the recess of the "Thrust piece".

10 Screw the "Screws" (1) of the "Clamping disc" (2). The torque settings for the "Bolts" are detailed in the chapter "Technical Data".

11 Mount the "Nozzle" as described in the pargraph "Dismantling the nozzle".

12 Label the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" in such a manner that if is unmistakably assigned to the corresponding "Screw barrel".


13 Dismantle the "Extension" of the "Piston rod" of the "Nozzle contact cylinders".

14 Mount the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" for the current "Screw barrel". The key surface (1) must be vertically positioned to ensure proper closing and opening of the purge guard. The torque settings for the "Bolts" are detailed in the chapter "Technical Data".

15 Fit the "Heater bands" hand-tight to the "Screw barrel" and mount the "Material hopper feed throat" if necessary.

16 Displace the "Guarding" with the stroke measuring system of the "Nozzle". If the new "Screw barrel" is larger than the old one, move the stroke measuring system to the right, away from the "Nozzle platen".

17 Mount the "Nozzle" and / or "Nozzle head" as described in this chapter.

18 Swivel the "Injection unit" in towards the "Nozzle platen".

19 Screw in the "Clamping bolt". The torque settings for the "Bolts" are detailed in the chapter "Technical Data".

20 Install the cover of the "Guarding" of the "Injection cylinder".

21 Prepare the machine as described in the "Operation" chapter in the paragraph "Test run without material".


23 Press the "Injection unit back" key. The "Piston rods" of the "Nozzle contact cylinders" are moved out.

24 Open the "Safety gate" on the operator and rear side.

1


25 Scre in the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen".

26 Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical stop.

27 Mount the "Nozzle" in reverse order as described in the paragraph "Dismantling the nozzle".

28 Recalibrate the stroke measuring system of the "Nozzle" (see "User manual").

29 Check the nozzle centring as described in chapter "6.2.3 Levelling the machine".

6.2.5.4 Dismantling the screw tip

1 Dismantle "Nozzle" and / or "Nozzle head" as described in this chapter.

2 Dismantle the "Screw" as described in this chapter.

ATTENTIONLeft hand thread! When removing or changing the screw tip it should be noted that the screw tip is fi tted to the screw with a left-hand thread!

3 Screw out the "Screw tip" using a special tool (option).

"Screw tip" with "Back fl ow check with ring".


"Screw tip" with "Back fl ow check with ring".


4 Thoroughly clean the components of the "Screw tip”. Use wire brush or brass brush.







Lubricate all threads of the new or cleaned "Screw tip" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F).


6.2.6 Cleaning the barrel, material changesThe increasing requirements for quality fi nished plastic articles necessitate the frequent and thorough cleaning of all components which come into contact with plastics.

6.2.7 Purging out with virgin polyethyleneThis process ensures an almost total purging of the previous material. However the polyethylene must in turn be forced out of the screw and barrel by the new material. It is not usually necessary to clean the screw by hand.

6.2.8 Purging out with a barrel purging agent.The purging compount is usually a colourless, high molecular weight, thermoplastic material which at approx. 100 °C (212 °F) is viscoelastic, but does not fl ow, melt or stick. In the form of an elastic plug, it pushes the previous material from the screw barrel. Usually, it is not necessary to clean the screw by hand.

Before cleaning shut-off nozzles and open nozzles must be removed and the nozzle temperature lowered. The temperature of the screw barrel should stay below (below 300 °C / 572 °F), injection pressure should be set to minimum or slightly above if required.

6.2.9 Cleaning the screw barrel

ATTENTIONThe screw must never be cleaned with a gas burner, a sand blast system or by glowing out!

These methods result in the loss of the mechanical and technological characteristics of the screw. In such a case, all warranty claims expire.

The screw must be cleaned with a brass brush only. Using a wire brush can damage the surface. We also recommend the use of a blast system with thermoset particles.

The barrel is cleaned with a rotating brass brush mounted to a long rod; a hand-held electric drill or similar device can be used to drive it.

6.2.10 StorageWhen storing the barrel it has been found effective to fi ll the barrel with about (200 g / 7 oz) of silica gel or similar desiccant and seal the openings. The screws should be kept in plastic sleeves, also containing silica gel. This will largely prevent corrosion.

SM1GB0MA0115TW Chapter 6.3 - 1

6.3 Hydraulics

6.3.1 General informationThe hydraulic system of the machine has a number of benefi cial features:

• Easily accessible hydraulic system.

• Energy saving pump with electric adjustment enables smooth movements with high precision and extremely short dry cycle times.

• The hydraulic components are arranged so that pipes and hoses are reduced to a minimum.

• Maintenance-friendly construction.

• Full fl ow fi ltration keeps the oil quality high for long periods.

6.3.2 Pump unitThe pump assembly comprises a speed-controlled servo-motor, a pump carrier, a pump carrier support, a damping component and the fi xed displacement pump.

The pump assembly is located at the rear side of the machine in the clamping-side upright of the base frame.

A compressed oil line connects the pump unit with the pump block. The vacuum oil line leads to the oil tank.

There is no way of closing the line between hydraulic tank and pump unit (shut-off valve as an option).

6.3.3 Hydraulic tankThe hydraulic tank is a fi xed part of the machine frame and is equipped with a fi ller cap with strainer, venting fi lters, and an oil level indicator with electrical monitoring and a temperature sensor.

The oil tank may only be fi lled through the strainer of the fi ller cap. This can be found within the machine frame close to the end platen.

The oil, of cleanliness class 17/15/12 acc. to ISO 4406 (Class 6 acc. to NAS 1638), must be prefi ltered through a mobile fi ltration unit fi tted with a 3 μm mesh fi lter.

The hydraulic tank is equipped with connectors for an external oil fi ltration unit.

The hydraulic tank is cleaned via the front-side cleaning cover.

SM1GB0MA0115TWChapter 6.3 - 2

6.3.4 Pressure fi lterTo improve the reliability and longevity of the hydraulic components and seals, a non-bypass pressure fi lter (fi lter mesh 5 μm absolute) is provided in the main pressure line of the hydraulic system. The pressure fi lter is fl anged to the pump block.

The pressure fi lter has an electrical clogging monitor which sends a warning message to the control screen if it is triggered.

If this message has not disappeared by the time the oil has reached its preheating temperature, the fi lter element must be replaced at once.

CAUTIONTo ensure trouble-free operation and long service life of the hydraulic components, only original fi lter elements may be used!

6.3.5 Oil coolerIn the oil cooler, cooling water is directed through the cooling lines which are surrounded by hydraulic oil, so that at the appropriate water fl ow rate and temperature adequate cooling of the hydraulic oil can be ensured.

It is essential to ensure that the water used is maintained at the quality detailed in "Maintenance" chapter. Otherwise a water fi lter (option) must be fi tted in the supply to protect the operation of the cooling water shutoff valve.

This regulates the cooling water fl ow and maintains a constant oil temperature by opening and closing the water supply as appropriate.

6.3.6 Control and displayThe oil temperature is measured in the oil tank. This temperature is indicated on the screen of the machine control unit to the operating personnel.

SM1GB0MA0115TW Chapter 6.3 - 3

6.3.7 Pressure settingThe speed-controlled servo motor takes care of the hydraulic pressure setting for all functions.

The control is effected by entering the corresponding pressure for each function on the control screen. Pressures are entered in "bar" (psi).

6.3.8 Speed setting The servo motor takes care of the hydraulic speed setting for all functions.

The control is effected by entering the corresponding speed for each function on the control screen. Speeds are entered as absolute values (mm/sec, inch/sec).

6.3.9 Hydraulic oil preheatingThe oil temperature values depend on the oil viscosity used (HLP32/HLP46).

As soon as the hydraulic pump is started, the cold hydraulic oil is automatically preheated to a temperature of bis das Hydrauliköl 40 °C (104 °F) HLP46 (HLP32 30 °C (86 °F)) .

While the oil temperature is below this value, the screen shows an error message and the machine can not be moved. After reaching the 40 °C (104 °F) HLP46 (HLP32 30 °C (86 °F)) mark, the oil preheating switches off and the machine is ready for operation.

While the IMM is running, the oil temperature is regulated to a constant 45 °C (113 °F) HLP46 (HLP32 35 °C (95 °F)). This is achieved by opening and closing the cooling water valve on the oil cooler.

If the oil temperature exceeds 60 °C (140 °F) HLP46 (HLP32 50 °C (122 °F)) , an error message is shown on the screen. If the temperature exceeds 65 °C (149 °F) HLP46 (HLP32 55 °C (131 °F)), the control switches the machine hydraulics off.

The reason for the oil’s overheating must be established and the fault remedied (e.g. water supply failure, cooling water shut-off valve on oil cooler closed.)

After operating the emergency stop button once, the hydraulics can be restarted. In this way, the hydraulic oil is cooled. No movements (from the clamping and injection unit) are possible during this phase.

ATTENTIONTake care of the conditions of installation and environment (Technical data chapter)!

SM1GB0MA0115TWChapter 6.3 - 4

6.3.10 Hydraulic core pullerThe hydraulic core puller (option) consists of a base plate on which the required hydraulic valves are installed and which includes the user connections (NW 6 or NW 10).

Installation sites of the function modules:Core puller Clamping unit: Ejector block

Core puller Nozzle side: Distributor block - base frame

The hose assemblies and fi ttings belonging to the mould’s core puller cylinder are not included in the delivery.

It should also be noted that the maximum system pressure is 250 bar (3625 psi). All connections and fi ttings must be able to withstand this pressure!

Hydraulic core pullers may be connected and put into operation only by a hydraulics expert. The safety regulations in the "Safety" chapter are to be followed without fail!

SM1GB0NA0115TW Chapter 6.4 - 1

6.4 Pneumatics

6.4.1 Pneumatic core pullerThe pneumatic core puller (option) comprises an electrically actuated 5/2 pneumatic valve and all the consumer connections for a 6 mm (0.24 inch) bore plastic pipe.

This function module is mounted onto the central console or on the media block of the clamping platen. The connection to the mould’s core puller cylinder is not supplied with the IMM.

ATTENTIONIt should be noted that the compressed air used should be dried and lubricated and limited to a pressure of 6 bar (87 psi). All connections and fi ttings must be able to withstand this pressure!

6.4.2 Air supply unitThe air supply unit (option for all pneumatic consumers) cleans the resource compressed air from liquid and solid matter and controls the air pressure.

1 Setting knob pressure control valve

2 Condensate separator

3 Pressure gauge

4 Condensate reservoir

5 Drain screw

The air supply unit should be used only with properly processed compressed air without any aggressive components.

A fi lter with a water trap separates the compressed air from solid contaminants and water. This protects the pneumatic components fed by it from premature wear.

1

2

3

4

5

SM1GB0NA0115TWChapter 6.4 - 2

EWAGB0OB0814TW Chapter 6.5 - 1

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

The defi ning feature of gas injection is the fi lling of the mould cavity with two fl uids. One fl uid is the polymer melt and the other is a gas, as a rule nitrogen (N2).

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

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

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

The "Airmould unit" is made up of a gas pressure control and a compressor unit.

The main components of the gas pressure control are a pressure regulation module and an electronic control unit integrated into the IMM "Control unit".

The pressure regulators for regulation of the gas pressure in the machine nozzle or mould needles, are compactly built units and can thus be positioned very close to the gas injection point. Four pressure regulators can be controlled by one standard electrical control.

EWAGB0OB0814TWChapter 6.5 - 2

The main parts of the pressure generator are a high pressure compressor, drive motor, gas bag, and accumulator bottles.

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

SM1GB0PA0115TW Chapter 6.6 - 1

6.6 Electrics

6.6.1 Electric drive 6.6.1.1 Speed-controlled servo motor

The pump unit is driven by a speed-controlled servo motor.

The drive motor is coupled directly to the hydraulic pump and connected to suit the operating voltage.

Service and connection work on the terminal rail may only be carried out by an authorised electrician!

6.6.2 Switch cabinet1 Switch cabinet Main cabinet

2 Switch cabinet Base frame

3 Switch cabinet Heating

1 3 2

SM1GB0PA0115TWChapter 6.6 - 2

6.6.2.1 Switch cabinet layout Main cabinet

1 Main machine connection (main switch)

2 Mains fi lter according to the wiring diagram

3 Power choke, depending on the supply voltage

4 ACOPOS supply modules according to wiring diagram

5 Automation PC - undertakes control and visualisation tasks

6 PowerLink - ACOPOS/Panel (yellow)

7 Earth terminals

8 Safety relay

9 CAB PCB - Input/Output - Safety technology assembly, Input/Outputs and Options

10 Distribution terminals

11 X020 Modules - Input/Output - Assembly

12 Ethernet Switch

13 Main barrel heating contactor, optionally main mould heating connector

14 Sensor lines (green)

15 PowerLink (yellow)

16 Cable protecting device according to wiring diagram

17 Kers contactor

1

2345678

9

10 11 12 13 14 15 16 17


6.6.2.2 Switch cabinet layout Base frame

1 Euromap 67 interface

2 Input/Output assembly Euromap 67 interface

3 Interface robot full integration

4 MB PCB - Input/Output - Assembly for inputs/outputs on clamping side and/or options

2

4

3 1


6.6.2.2 Switch cabinet layout Heating

1 KERS

2 Nozzle heating

3 Power choke, depending on the supply voltage

4 PM8 control board

5 PM8 power board

6 Sockets for barrel heating

3

14

2

6

5


Only qualifi ed electricians may connect the machine to the electrical power supply system. Switch off the on-site main switch and secure it against reconnection (e.g. by means of a danger sign at the main switch).

In the factory the machine has been equipped with a PEN terminal for the connection to a TN-C network (4 conductors).

• Open the switch cabinet

• Connect the mains cable to the mains switch and the PE terminal (to N and PE terminal in the case of TN-S network)

• All clamping bolts in the switch cabinet must be checked for secure fi tting and, if necessary, retightened.

• Check the modules in the control insert and connection plug for secure fi tting.

• Close the electrical cabinet

• Check all plug connectors of the control lines for the valves and safety switches for secure fi tting.

Only peripherical devices which correspond to theVDO requirements and the EMC regulations (electromagnetic compatibility) of electrical operating materials may be operated on the machine. Cabling which was additionally fi tted to the machine by the proprietor must correspond to the EMC regulations (electromagnetic compatibility).

EWAGB0QC1214MC 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 operator friendlinesss, speed and precision.

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

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

6.7.2 Operator panelThe control panel is divided into:

• 15"-TFT colour monitor with unrestricted touch-screen functions for operation and display

• 2 rows with soft keys to select the machine functions

• 48 membrane keys for operating the machine axes and the optional equipment

• Space for another 7 optional mechanical switches / keys

• 10 luminous ring membrane keys are available for the main machine functions (drive, heaters, operating modes).

• 2 USB interfaces can be used for the connection of data carriers (e.g. USB stick, printer, keyboard) or as an access system in combination with a password.

• More interfaces (2 USB and 1 Ethernet interfaces) are located at the rear side in the switch cabinet.

EWAGB0QC1214MCChapter 6.7 - 2

6.7.3 Explanation of the pictureFlexibility

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

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


Holding pressure

The combination of tabular input and graphic represenation facilitates the setting of the machine with the number of profi le points being selected by ticking. A status bar on the extreme right of the screen will quickly inform you on the current machine status. Furthermore, 3 confi gurable status bars are available. By entering the machine settings in physical units and storing them on an USB stick, machine data records can be exchanged among machines of different size.


Actual value graphics

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


Cycle time analysis

Analysis at a glance. The confi gurable cycle time analysis can be used for process optimisation and, at a glance, shows the effects in the value change cycle to individual movements and/or the total cycle. A complete overview is given by determining a reference cycle compared to the previous and the current cycle.


Alarm system

The production process can be backtraced by means of a comprehensive alarm / logging concept with different fi ltering possibilities. Reaction times in the event of plant failures are shortened by the automatic dispatch of email messages.

6.7.4 Saving / Printing USB interfaces

Data / printouts can be stored / sent to USB data carriers and/or USB printers compatible with WindowsTM by means of 2 USB interfaces located laterally on the operator panel and 2 other USB interfaces in the switch cabinet.

Ethernet interfaces

1 Ethernet interfaces with RJ45 connections are available in the machine switch cabinet for the integration in WAN/LAN networks, such as save / load machine data to / from a network server, or send print jobs to a network printer server, or for the purpose of remote diagnosis.


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 / EPL connection

Short-distance link connection (SDL)

Ethernet Powerlink connection (EPL)


Touch display unit AP9xx

The display unit is composed of two components: an automation panel device and an automation panel link plug-in module. These two components, plugged together, build the complete display unit. The resolution is 1024 x 768.

Automation panel 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 release of unintended functions when touching the touch screen or pressing the keys or control devices.

Use a moist cloth to clean the automation panel device. Only use water with a washing-up liquid, screen cleaner, or alcohol (ethanol) for moistening the cloth. Do not spray the cleaning agent directly on the automation panel device but spray it on the cloth! Under no circumstances use aggressive solvents, chemicals, scouring agents, compressed air, or steam jet.Clean the display with the touch screen at regular intervals.


Automation panel link plug-in module SDL

The automation panel link plug-in module is the interface between an automation PC and an automation panel 9xx. Graphic signals of an industrial PC (e.g. automation PC monitor / panel output) are received, processed, and passed on to the automation panel 9xx. In the opposite direction, the touch screen, USB and SDL data, for example, are transferred to the respective interface of the industrial PC (e.g. automation PC). By means of simple slide-in technique, this plug-in module is plugged into the slide-in slot of the automation panel 900 and fi xed to the automation panel by means of the two fi xing screws (max. tightening torque 0.5 Nm).

Display cable SDL cable 5CASDL.0xxx-00Fixing screws

Voltage supply+24VDC In

Panel IN(via SDL)

This cable is necessary for the transmission of the graphic / touch screen / USB signals between display unit (automation panel link plug-in module) and automation PC.

ATTENTIONThe SDL cable may be connected and disconnected in the dead state only.

Pin assignment

CasingCasing


Key unit 5E9000.xx

Is used to operate the basic machine functions and special equipment. Due to the slide-in strip technique, it can be easily adapted to customer wishes.

• Voltage supply: +24 VDC

• Bus interface: 2 x Ethernet Powerlink (EPL)


Automation PC

The Automation PC with Intel® Core i technology is available for applications with the highest demands in terms of processor performance. These processors, which were especially developped for mobile computing, offers many advantages for industrial use, too. High computer power is combined with low power input. The chip set includes an integrated graphics with optimised storage utilisation between system and graphics.

The following individual components are absolutely necessary for operation:

• System unit

• CPU board

• Heat sink (depending on the CPU board)

• Main memory (depending on the CPU board)

• Drive (mass memory, such as Compact Flash card or hard disk) for the operating system

• Software

or

Interface Option 1

status LEDs:

Monitor / panel / interface

Voltage supply

* Depending on the bus type used:

Interface Option 2


Battery:

A lithium battery (3 V, 950 mAh) buffers the internal real-time clock (RTC) as well as individually stored BIOS settings and is located under the black cover. The buffer duration of the battery is at least 4 years (at 50°C, 8.5 μA of the components to be supplied and a self-discharge of 40%).

Battery

status LEDs:

Power key

Reset key


I/O modules

Three basic elements form a single module: Bus module - electronic module - fi eld terminal

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 fi eld terminal - ensures maximum packing density

7 Push-in terminals - no tools required for the handling of all standard connection cross sections

8 Coding - seamless works and customer coding

1

8

7

6

5

4

3

2


X20BR9300

The X20 System is connected to the X2X Link with the bus receiver BR9300. The module is equipped with a feed for the X2X Link and the internal I/O supply.

Alternativ zu X20BR9300 -> X20BC0083/X20PS9400

X20BC0083

The BC0083 Bus Controller enables the connection of X2X Link I/O nodes (modules) to POWERLINK (standard protocol for Fast Ethernet).

X20PS9400

The PS9400 supply module is used together with an X20 Bus Controller (e.g. X20BC0083). It is equipped with a supply for the Bus Controller, the X2X Link and the I/O supply.

X20DI9371

The module DI9371 has 12 inputs in single conductor technology. The DI9371 is designed for sink input wiring.

X20DO6322

The module DO6322 has six outputs in single or doubleconductor technology. The X20 standard terminal can be used 6x for continuous single conductor wiring. Double conductor wiring is possible with the 12x terminal. The DO6322 is designed for source output wiring.The nominal output current is 0.5 A.

X20DO9322

The module DO9322 has 12 inputs in 1-conductor technology. The DO9322 is designed for source output wiring. The nominal output current is 0.5 A.

X20DO8332

The module DO8322 has eight inputs in 1-conductor technology. The nominal output current is 2 A. The output supply is fed directly at the module. This means that no additional feed module is necessary. There is no connection from the module to the I/O supply potential on the bus module.

X20AI4632

The module AI4632 has four inputs with 16-bit digital converter resolution. It can be switched between current and voltage signal (+/- 10 VDC) with the aid of different connection terminals.


X20AO4632

The module AO4632 has four outputs with 16-bit digital converter resolution. It can be switched between current and voltage signal (+/- 10 VDC) with the aid of different connection terminals.

X20AT6402

The module AT6402 has six inputs for J, K, N and S thermocouple sensors. A terminal temperature compensation is integrated in the module.

X20PS4951

The module PS4951 has four +/-10 VDC voltage supply channels for the potentiometer supply.

CS 1070

The CS 1070 module is equipped with a CAN bus interface. Furthermore, an additionally connectable terminating resistor is included.

CS 2770

The CS 1070 module is equipped with 2 CAN bus interfaces. Furthermore, an additionally connectable terminating resistor is included.

HC6GB0RC0714MC Chapter 7 - 1

7 Operation

7.1 General information

For a number of reasons we would recommend commissioning of the IMM by Battenfeld personnel. This is not only for warranty reasons, but because at the same time:

• The machine can be checked for any transport damage or installation and connection faults.

• The operating personnel will be introduced to the IMM.

• Additional advice on operation, maintenance and repair can be given.

Magnetic fi eld hazard! In the immediate proximity of the magnetic fi elds of magnetic quick-action mould mounting systems (option), cardiac pacemakers, hearing aids, or disks etc. will be impaired!

These magnetic fi elds will still be present after switching off the machine at the main switch. Only after demagnetising the magnetic modules will the magnetic fi elds be neutralised, i.e. the hazard will no longer be present.

CAUTIONEvery 2500 operating hours, the barrel heater bands must be checked for tightness at operating temperatures!

Check the nitrogen pressure in the pressure vessel (option) at regular intervals as described in this chapter!

HC6GB0RC0714MCChapter 7 - 2

7.2 Initial start-upATTENTION

For test purposes, the injection unit was operated with the following material:Polystyrene STYROLUTION PS 454N (HIPS) processing temperature 180°-260 °C/356°-500 °FIf required, rinse screw barrel with a suitable cleaning material.

1 Observe the operating manual and in particular the safety regulations in the "Safety" section.

2 Unload, transport, install and level the machine as described in the "Transport - Installation" section.

3 Prepare the hydraulic system as described in the chapter "Transport - Installation".

4 Prepare the water system as described in the "Transport - Installation" section.

5 Turn on water supply to oil cooler

6 Prepare the pneumatic system as described in the "Transport - Installation" chapter

7 Open the air supply from the compressed air system to the air supply unit (option), mechanical scotch (option).

8 Prepare the electrical equipment as described in the chapter "Transport - Installation".

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

10 Ensure that there are no highly combustible and explosive air mixtures near the screw barrel heating

11 Ensure that no easily combustible materials, e.g. styrofoam, rags etc., or explosive air mixtures are near the inlets of the radial fans.

12 Lubricate lubrication points, as described in the "Transport - Installation" chapter

13 Prepare the Airmould unit (option) as described in the "Airmould" chapter.

For the preparation of a mobile Airmould unit (option) please refer to the separate operating manual.

14 Switch on drive ("Drive On" key).

The standard machine has an oil preheating system, and can not be run until a hydraulic oil’s operating temperature has been reached (after about 15 min.).

15 Clear any error messages which appear (see "UNILOG B6 User’s Manual", "List of all alarm messages" section).

16 Mount the mould as described in the "Transport - Installation" chapter and adjust the clamping force.

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


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 case of danger. If it has been operated, it must be released after the fault or the cause of the external emergency stop (periphery, e.g. the robot) has been cleared, by turning it in the direction of the arrow. Then the machine is switched on again as described in the paragraph "Operation", and if necessary, the mould cleared of the moulding by means of the ejector.

The starting position of the machine is: Mould fully open, ejector, nozzle and screw back, core puller (option) out.

7.4 Checking the nitrogen pressureCheck the nitrogen pressure in the pressure vessel (option) before and during operation. In case the nitrogen pressure falls short of the indicated value (see name plate), nitrogen has to be refi lled.

The safety regulations in the chapter "Safety" are to be followed without fail!Work at pressure vessels may only be carried out by specially trained personnel!Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released!Risk of explosion! Only use nitrogen "N2" as gas!

For instructions on how to refi ll, reduce and check the nitrogen pressure, please refer to the "Transport - Installation" chapter.

1 Check at least once within the fi rst 40 operating hours. Major losses in nitrogen will immediately be detected and be compensated.

2 In case no losses have been detected during the fi rst inspection, the next inspection is to be carried out after 500 operating hours.

3 After this inspection further inspections may be carried out at an interval of 1000 operating hours.


7.5 Test run without materialAfter commissioning or changing the mould, the movements of the various units should be tested before running a few manual cycles with a mould mounted.

The safety regulations in the chapter "Safety" are to be followed without fail!

1 Check whether the switch cabinet, safety guards and safety gates have been properly installed or closed.

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

3 Switch on the supply voltage (low voltage distribution) - commissioning only.


5 Release the emergency stop button(s) on the machine by rotating a quarter of a turn clockwise.

6 Open the water supply from the cooling system to the individual users (oil cooler, cooling water fl ow governor, etc.) - commissioning only

7 Open the air supply from the compressed air system to the air supply unit (option), 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 a power-operated safety gate (option).

10 Switch on drive ("Drive On" key).

This action also starts the oil preheating. Now, you have to wait until the hydraulic oil is heated up to a minimum of 40 °C (104 °F) HLP46 ((30 °C (86 °F) HLP32)

Start the pump without load and run it for a few seconds to allow for adequate lubrication.

11 Switch on bypass fi ltration unit (option).


Before operating the machine the safety regulations in the operating manual(s) of any peripheral equipment must be followed without fail!

12 Commission peripheral equipment (option) according to the operating manuals and set them to the starting position, i.e. the position in which no damage to the devices or to machine components is possible.

13 Clear any error messages which appear (see "UNILOG B6 User’s Manual", "List of all alarm messages" chapter).


15 Log on to the control.

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

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

16 Setting the set values

(see B6 user manual)

The set values for "Injection" are to be set as low as possible for a respectable injection cycle. Otherwise the mould can possibly be overpacked. When opening the mould and using magnetic quick-action mould mounting systems (option) in particular the chucking power can be exceeded.For moulds with a smaller base the ejector force may exceed the retention force of the clamping elements which will cause the mould to disengage.

During operation "without material" it is necessary that no shot volume is entered, thus the set value is 0. In this, case the screw is only to be retracted by means of decompression in order to avoid the injection of material.

Set the set values for "Injection", "Locking force" and "Ejector" as low as possible for an acceptable injection cycle. Otherwise forces may be present when opening the mould which can possibly exceed the limit range of the clamping elements!


Fire hazard! No smoking! Make sure that there are no fl ammable liquids, open fl ame, etc. near the screw barrel heating or barrel cooling (option)!

No drawn-in material or explosive air mixtures may be near the inlet area of the radial fans to the barrel cooling (option)!

17 Remove all materials, liquids and objects which should not be near the injection unit.

18 Press "Heating on" key (switch on barrel heating).

(see B6 user manual)

19 Bring the machine to the following starting position:

Mould open

Ejector fully back

Nozzle back

Screw back

Core puller out (option)


20 Press "Automatic mode" key.

Operating and other personnel may only stand in front of the machine on the operator’s side during operation!

21 Press "Mould close" key; an automatic cycle is started.

The "Semiautomatic" modes can be started by closing the safety gate (option).

In case of power-operated safety gates at the clamping unit, these gates will be opened automatically at the end of the cycle in the "Semiautomatic" operating mode.

During the test run, listen for any unusual noises and check the function of the safety gates.

The "Fully automatic" and "Semiautomatic" modes are interrupted by pressing the "Manual mode" key or an emergency stop button.

Any leaks which arise in the fi rst few operating hours can usually be cured simply by tightening the screw connections.

22 The "Automatic" operating mode can be stopped at the end of the cycle by pressing the "Open mould" key during the cycle. In this case, the error message "manual end of production initiated" is displayed. After the cycle has been interrupted, further operation can be initiated by pressing the "Close mould" key.


7.6 Filling the material hopper

1 Make sure that the main switch is switched off and secured against unauthorised reconnection.

Surfaces marked with the "No step” symbol must not be stood on!

If the material hopper, the material feeder or the stuffi ng device are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for fi lling!

2 Move the climbing aid in front of the machine.

3 Clean the material hopper and check for foreign particles. For this reason the use of open material bags should be avoided.

Follow the plastic manufacturers’ instructions!When processing plastics which give rise to harmful gases dusts or vapours, the proprietor of the machine has a duty to provide suitable extraction for the protection of operating personnel!

CAUTIONThe operator has a duty to ensure no foreign bodies enter the material hopper of barrel throat!

4 Place material hopper to mid position.

5 Fill in material

6 Place material hopper above the feed throat of the screw barrel.

7 Remove climbing aid from the working area of the machine.


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 profi le (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.


9 Select the desired program "Automatic” or "Semiautomatic”

Depending on the program selection either press the "Close mould" key or close the safety gate (see step 22 in the "Test run without material" section) to start the machine.

In this way several cycles are run.

The movements of the various units, the settings and the quality of the mouldings are now to be checked. Depending on the application, appropriate corrections are made to the various set values in order to achieve the quality required for the moulding.

Once all the set values have been entered, they can be saved to avoid unnecessary data loss.

For additional security the set values complete with mould number and part number should be printed out and placed in the Operating Manual.

For procedure see the UNILOG B6 User manual, chapter 25 "Data records".

10 Log off from the control

CAUTIONTo prevent set value entries by unauthorised persons, the user must log off after fi nishing setting!

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

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

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".


7.8 Operation

The operation of the machine does not differ from the procedure described in paragraph "Test run with material" and the procedures described in this section.

After each shutdown and before each start-up of the machine, the safety devices have to be checked after switching on the main switch as described in the "Transport - Installation" chapter!The safety regulations in the chapter "Safety" are to be followed without fail!

For the fi rst few hours in which the machine is used under production conditions, the following should be monitored in particular:

1 The hydraulic oil temperature.

The optimum effi ciency of the hydraulic oil is between 45 °C und 50 °C (113 °F und 122 °F) HLP46 (35 °C und 40 °C (95 °F und 104 °F) HLP32).

The current oil temperature will be displayed on the "Hydraulics" screen page.

2 The proper fi t of the tiebar nuts.

The tiebar nuts may loosen due to the constantly changing loads. Therefore, the clamping plates of the tiebar nuts must be tightened and checked for security after the fi rst 100 operating hours.

3 The screw barrel heater bands

The barrel heater bands must be checked every 2500 operating hours for security at operating temperatures.

4 The nitrogen pressure within the pressure vessel (option); see "Checking the nitrogen pressure" chapter.

Periodical checks should be performed during operation at regular intervals and according to the procedure described in the "Maintenance" chapter.

Visible defects are to be remedied immediately.

Remedy damage immediately. Hydraulic oils escaping at high pressure can cause severe injuries and fi res!This applies especially to hydraulic fi ttings and hose assemblies.


7.9 Shutting down the machine


2 Set peripheral equipment (option) to the starting position and switch off any peripheral equipment according to its operating manual.

3 Pull the hopper away from the feed throat of the barrel

4 Move the core pullers out of the mould if appropriate.

5 Move the clamping platen to the starting position (Mould open). If necessary remove the moulding(s) from the mould using the ejector

Burns hazard! Do not touch escaping material!

6 Swing the material hopper from the inlet area of the screw barrel to the centre position

7 Press the "Injection unit back" key.

8 Place an appropriate reservoir in front of the nozzle and purge the remaining material at short intervals.

9 Switch off drive ("Drive off" key).

10 Switch off the heater ("Heater off" key)

11 Close and relief the cooling water supply (add antifreezing agent, if necessary) from pressure

12 Close and relieve the compressed air system (option) from pressure



7.10 Extended shutdown

1 Shut down the machine as described in "Shutting the machine down”.

Swing the material hopper to the emptying position and fi ll the remaining material into an appropriate container.

2 First free the screw barrel and the screw from the remaining melt and purge out with polyethylene.

3 Depending on the material to be processed, the nozzle and the screw must be removed and cleaned.

4 Preserve the cavities of the mould according to the manufacturer’s instructions.

5 For a hydraulic system with integrated pressure accumulator (option) defl ate the nitrogen as described in section "Transport - Installation".

6 Treat all bare parts with a anticorrosive agent.

7 Empty the cooling water system, blow out with compressed air and treat with anticorrosive agent


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. The dismantling of a mould fastened with a quick-action mould mounting system basically corresponds to the following description. The only differences will be in the Remove mould of the clamping platen / nozzle platen paragraphs. To this end use the appropriate control elements at the operator panel. See also paragraph "Mould mounting using quick-action mould mounting systems" in the "Transport -Installation" chapter

1 Press the "Mould Close" key and close the mould.

The mould may only be dismantled by an authorised skilled technician!

2 Disconnect the ejector coupling (mould to hydraulic ejector cylinder).

Burning hazard if touched! At mould temperatures above 60 °C (60,00 °C) wear appropriate PPE!

3 Let the mould cool down to a safe temperature (material dependent).

4 Prepare the mould for dismantling (Disconnect cooling hoses, heating cables etc.).


5 Mount the safety strap holding the two mould halves together.

The safe working load of the lifting equipment must equal or exceed the weight of the mould!

6 Mount the lifting gear at the mould.

7 Slightly tension the lifting gear.

8 Press the "Setting" key.

9 Loosen the mounting elements of the mould on the clamping platen.

10 Move the clamping platen back.

11 Loosen the mounting elements of the mould on the nozzle platen.

12 Remove them from the centering hole in the nozzle platen.


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

13 Lift the mould horizontally out of the opened clamping unit.

14 Protect the mould according to the mouldmaker’s instructions and prepare it for storage.

7.11.2 Further measures for shutting down1 Let the heating elements and their guardings, temperature control units and their fl ow and

return lines and their couplings and mounting elements cool down to a safe temperature.

2 Move the piston rods of the hydraulic cylinders in the setting mode as far as possible into the hydraulic cylinder to protect them from corrosion.

In case of a possible disassembly, release any remaining pressure by carefully loosening (but not completely undoing) the appropriate hydraulic screw connection.

If the place of installation is to be changed, the clamping and the injection unit has to be moved to the transport position as described in "Changing the place of installation".

3 Press "Drive stop" key.

4 Turn off the main switch and use a padlock to prevent accidental reconnection.

Cleaning materials are classed as fl ammable liquids, hazardous to health. The manufacturer’s instructions are to be followed without fail!

5 Dismantle nozzle (and nozzle head) as well as screw and screw barrel and clean them.


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) defl ate the nitrogen as described in section "Transport - Installation".

Burning hazard if touched! At oil temperatures above 50 °C (50,00 °C) wear appropriate PPE! Avoid any skin contact! If hydraulic oil gets into the eyes, rinse carefully with water and consult a physician!

2 Clean the area round the venting fi lter.

3 Thoroughly clean the area around the fi ller and screw plugs on the transport and storage containers.

4 Unscrew the venting fi lter lock and remove the complete venting fi lter from the pipe socket.

Fire hazard! No smoking! Make sure that there are no fl ammable liquids, open fl ame, etc. nearby!

Environmental hazard! In case of leaking hydraulic oil follow the legal provisions and regulations without fail!

5 Empty the hydraulic tank by means of a pump unit via the pipe socket. The suction hose must reach to the bottom of the hydraulic tank.

The pump unit must be permissible for hydraulic systems.

The tank must be approved in accordance with the applicable laws and regulations and must be dimensioned to be able to hold the hydraulic oil volume (see "Technical Data" section).


6 Place the venting fi lter on the pipe socket again.

7 Clean the hydraulic tank

8 Remove the housing of the hydraulic fi lter. Dispose of the liquid in a suitable container, see chapter "Maintenance", "Hydraulic fi lter" paragraph.

When storing and disposing of hydraulic oils and used oil the local laws and regulations are to be followed without fail. The proprietor of the machine is responsible for proper waste disposal!

When disposing of the oil pan and cloths drenched with hydraulic oil the laws and regulations applicable must be followed without fail. The proprietor of the machine is responsible for proper waste disposal!


7.11.4 Emptying the cooling water supply


Burning hazard if touched! At water temperatures above 50 °C (50,00 °C) wear appropriate PPE!

1 Cut off the water supply to the oil cooler

2 Cut off the water supply (1) to the cooling water fl ow control.

3 Turn the two hand-wheels (2+3) of the cooling water fl ow control counterclockwise (Close cooling water fl ow).

4 Disconnect the cooling water supply and return lines from the oil cooler

5 Drain the cooling water from the supply and return lines of the oil cooler to appropriate systems or containers

6 Disconnect the cooling water return (4) from the cooling water fl ow control and drain the cooling water to appropriate systems or containers.

7 Disconnect the cooling water fl ow (1) from the cooling water fl ow control and drain the cooling water to appropriate systems or containers.

8 Turn both hand-wheels (2+3) of the cooling water fl ow control cw (Open cooling water fl ow) and drain the cooling water to appropriate systems or containers

9 Disconnect the cooling water fl ow and return (5+6) of the users and drain the cooling water to appropriate systems or containers

10 Connect the compressed air hose to the supply lines of the oil cooler and the cooling water fl ow control and blow out with compressed air.

11 Drain the remaining cooling water from the supply and return lines to appropriate systems or containers

12 Insert plugs into the fi ttings of the supply and return lines to protect them against contamination

1

6

5

3

2

4

3

2


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 risk of 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 suitable container; 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 all unpainted, unplated bolts must be preserved using an oily rust preventing agent.

21

3


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 power terminals.

3 Secure the supply lines against interference according to locally applicable regulations.

4 Place desiccant medium for protection of connecting terminals, relays, etc. from corrosion into the electrical cabinet.

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 fi lled with hydraulic oil; see chapter "Transport - Installation".

4 Replace the "Hydraulic fi lter" and "Venting fi lter" fi lter elements; see chapter "Maintenance".

The isolation value may only be checked and moist windings may only be dried by a qualifi ed electrician. The safety regulations in the chapter "Safety" are to be followed without fail!

5 Check the insulation values of the hydraulic motors windings.

6 Observe the service life of the battery in the control unit; see chapter "Maintenance".

7 Prepare the machine according to section "Transport - Installation".

8 Proceed in the same order as described in "Test run without material" to "Test run with material"


9 Maintain hydraulic system

After extended shutdown, in particular, if there are extreme climatic conditions, the movement of some hydraulic components (e.g. valves) may be restricted due to gumming or precipitations within the hydraulic oil. For this reason the machine should be carefully restarted at low set values for the movement speeds and pressures. Carefully observe whether all hydraulic functions have been carried out and the proper function of the machine is ensured.

If necessary, the machine should be fi lled and fl ushed out with a cleaning oil (HLPD according to DIN 51524 Part 2, Class ISO VG 32). These are hydraulic oils with cleaning additives (identifying letter "D" = "detergents").

After successful fl ushing, the machine should be refi lled and used with the standard hydraulic oil (HLP32/HLP 46).

10 Follow the procedures in the respective operating manuals without fail before restarting the peripheral equipment.


7.13 Changing the place of installation 1 Prepare the machine as described in "Shut down procedure".

2 Move the injection unit to its foremost position (into the nozzle platen) before changing the place of installation

3 Move the clamping platen to the "Mould open" position and adjust the maximum mould mounting height.

4 Open the clamping unit’s safety gates on the operator’s side and the rear and secure by a rope, around the machine frame tied to each handle.

5 Remove foundation bolts if necessary.

6 If the machine is to be moved to an external installation site, lift it using the appropriate lifting equipment, see chapter "Transport - Installation" and dismantle the levelling mounts.

7 Attach lifting equipment as described in paragraph "Transporting the machine" in chapter "Transport - Installation".

8 Transport the machine using the appropriate means of transportation (fork lifting truck, crane) as described in chapter "Transport - Installation"

9 If the machine is to be moved to an external installation site, secure the IMM with ropes suitable for the weight of the machine on the means of transportation (e.g. truck)

The complete machine may only be placed on a level surface capable of supporting the appropriate load.

10 Unload, install, level and commission the machine at the new installation site as described in chapter "Transport - Installation"


7.14 Disposal

The proprietor is obliged to dispose of all components, lubricants, hydraulic and gear oil as well as other aids (cleaning cloths, cleaning agents, etc.) according national and international laws and regulations.

This applies especially to those components which have been in contact with products hazardous to the environment (lubricants, hydraulic and gear oils).

Please contact the responsible authorities before disposal. You will receive detailed information on laws and regulations applicable, the facilities for disposal as well as on authorised waste disposal companies.

Ask your lubricant supplier for the safety data sheets according to DIN 52900 for the products they supply you with. Among others, these contain information on waste disposal.

If possible, the materials and substances should be recycled.

The provisions on waste disposal within the European Union (EU) can be found in the "Europäischen Abfallkatlogverordnung" (EAKV) ("European Waste Disposal Catalogue Regulation"). This regulation is to translate the provisions of the decision 94/3/EC on a waste disposal directory according to Article 1, section a of the Directive of the Council 75/442/EEC on wastes into the German legislation.

In the Directive of the Council 75/442/EEC measures on the avoidance, recycling and the disposal of wastes are described in Article 3; Article 4 contains the compliance with the principle of non-hazardous waste recycling and disposal. Article 5 stipulates the principles of the nearest possible and self-reliant waste disposal.

SM1GB0SA0115TW Chapter 8 - 1

8 Maintenance

8.1 MiscellaneousCareful installation and care are necessary for the reliable functioning of the injection moulding machine (hereinafter machine).

Daily visual checks help to prevent down times. Checks, maintenance work and the exchange of worn out parts should be undertaken at regular intervals. Only parts of the same quality (strength, material) and design may be used.

Breakdowns of the machine caused by inadequate or improper maintenance can result in very high repair costs and long periods of down time. Regular maintenance is therefore essential.

If you have questions about maintenance or service of the machine, please contact our Technical Service Department or one of our subsidiaries. The addresses can be found in the "Customer service" chapter.

The safety regulations in the "Safety" chapter are to be followed without fail!Before starting any maintenance or repair work the main switch of the machine must be switched off and secured against accidental reconnection!

8.2 Transport, storage and disposal of lubricants

Lubricants and hydraulic oils are environmentally hazardous products. For this reason, the local environmental laws and regulations concerning water, building, waste, transport, trade and safety at work must be observed.

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

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

There is therefore a need to make contingency plans for preventive measures in the case of any incident with oil. This includes the existence of such a plan itself, that suffi cient oil absorbing medium is in stock, that drains can be closed off and that tools and materials are available to prevent the spilled oil from escaping.

SM1GB0SA0115TWChapter 8 - 2

Ask your lubricant supplier for the safety data sheets according to DIN 52900 for the products they supply you with.

These cover:

• Chemical and physical properties.

• Protective measures, storage and handling.

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

8.3 Disposal of electrical and electronic components

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

8.4 Hydraulic oil and lubricant table

ATTENTIONNew machine:In principle, a test run of the machine in the factory is carried out with zinc-containing oil. However, the machine can also be operated with a comparable zinc-free oil When delivered, the remaining amount is approx. 5 %, therefore you must ask the respective oil supplier whether operation is possible when mixing is done in this ratio.

Second-hand machine:In consultation with the manufacturer / supplier of the oil, the operating company may - upon its own responsibility, change the oil type from zinc-containing to zinc-free oil.In principle, such a change of oil type should not be made since extensive technical problems could be caused.Wittmann-Battenfeld will not grant an approval!


Only use prefi ltered hydraulic oil of cleanliness class 17/15/12 acc. to ISO 4406!

*) Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO 4406; always prefi lter!

**) Only for air cooled three-phase motors

***) For ServoPower (Option). Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO 4406; always prefi lter!

****) H1 Food quality

Lubrication point Hydraulic equipment*)

Hydraulic equipment***)

Gearbox, axial bearing

Central oil lubrication

Central lubri-cation grease

and grease

Three-phase motor & electric

motors**)Pneumatics Linear guide

High - assembly

paste

Designation to DIN 51502

HLP 46DIN 51524 T2

HLP 32DIN 51524 T2

CLP 220DIN 51517 T3

CG 220DIN 51517 T3

K 2/3 R - 40DIN 51825

HLO 10 / CL 10DIN 51524 T1

KP2 N-20 DIN 51825

AgipOSO 46

AgipOSO 32

AgipBlasia 220

Agip ASP 220Agip Exidia 220 - Agip

ACER 10

Aral VitamGF 46

Aral VitamGF 32

Aral DegolBG 220

Aral DeganitB220 - Aral Vitam

DE 10

AVIA FLUIDRSL 46

AVIA FLUIDRSL 32

AVIA GEARRSX 220

Slideway oilRSU 220 - AVIA FLUID

RL 10-C

BP EnergolHLP-HM 46

BP EnergolHLP-HM 32

BP EnergolGR-XP 220

BP Maccurat220 D - BP Energol

HLP-HM 10

Castrol Hyspin

AWS 46

Castrol HyspinAWS 32

Castrol AlphaSP 220

MagnaglideD 220 SLX Grease Castrol Hyspin

AWS 10SPERROL

EPL2

NUTO H 46 NUTO H 32 SPARTANEP219

FEBISK 219 - SPINESSO 9

HYDRAN TS 46

HYDRAN TS 32 GIRAN 220 HYDRAN G220 Pluton EM CIRKAN 10

MobilDTE 25

MobilDTE 24

Mobilgear630

Mobil VactraOil No. 4 - Mobil Velocite

Oil No. 6

RENOLIN B 15

VG 46

RENOLIN B 15

VG 32

RENOLIN CLP220/220 Plus

RENEPCGLP 220 - RENOLIN B 3

VG 10

Q8Haydn 46

Q8Haydn 32

Q8Goya 220

Q8Wagner 220 - Q8

Haydn 10

Shell Tellus S2 M 46

Shell Tellus S2 M 32

Shell Omala S2 G 220

Shell Tonna S3 M 220

Aero Shell Grease 16

Shell Morlina S2 BL 10 Alvania WR2

TUNGEAR CGLP 220

(H1****)

TUNGEAR CGLP 220

(H1****)

TUNGREASE CSH2 (H1****)



TNK Hydrau-lic HLP 46

TNK Hydraulic HLP 32

TNK Reductor CLP 220 - - - -

Lukoil Geyser ST 46

Lukoil Geyser ST 32

Lukoil Steelo 220 - - - -

Gazpromneft Hydraulic HLP 46

Gazpromneft Hydraulic HLP

32

Gazpromneft Reductor CLP

220- - - -

WEICON Anti-Seize High-Tech


8.5 Maintenance chart

Every 160 operating hours

• All safety devices (1) or all safety guards installed (2) (including the mechanical scotch)

• Oil level in hydraulic tank (3)

• Overall condition of machine (visual check).

• Always keep the electrical cabinet closed

• Check the fi lter mat(s) in the electrical cabinet fans for clogging.

• Check hydraulic fi ttings, hose assemblies, cylinders, valves, pump(s) etc. for leakages

• Check air conditioning units (condensation water tank, fi lter), if present

• Check water piping and the respective fi ttings for corrosion and leakages

3

4412 2

3



• Spray all bare parts (tiebars, piston rods, guide rails, linear bearings injection units), where there is no movement with a corrosion inhibitor

• Lubricate grease points on linear guide

• Remove emerging lubricating grease.

• Check scotch bar (option) for proper function

• Clean fi lter element of air supply unit (option)

• Checking the nitrogen pressure


• Operating manual available and correct.

• Check the heater bands for correct position and secure fi tting.

• Clean the switch cabinet, tighten all terminals in the switch cabinet, check cables (for damage, scorching)

• Clean the fi lter mat(s) of the switch cabinet, fan

• Test the emergency stop circuit.


• Check screw coupling and retighten screws if necessary.

• Replace hydraulic tank venting fi lter


• Check all stroke transducers for cleanliness and ease of operation.

• Visual check of electrical components.

• Check nozzle for wear and concentricity


• Test hydraulic oil (replace if necessary)

To establish the oil change interval suitable for the local operating conditions it is recommended to test the oil at fi rst after shorter intervals (e.g. monthly).

• Replace fi lter element of the hydraulic fi lter.

• Check all fi ttings for security and tighten as necessary.

• Check of insulation resistance and of the protective-conductor system.


• Change hydraulic hose assemblies

• Flush oil cooler and cooling water fl ow governors with a descaling solution.


8.6 Hydraulic system

Work on hydraulic system may only be carried out by a skilled hydraulic technician!If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury!

Switch off the main switch and use a padlock to prevent accidental reconnection. If the clamping platen, nozzle and screw are not in one of their end positions then the hydraulic system is relieved from pressure. Any residual pressure can be released by carefully loosening (but not completely undoing) a hydraulic screw connection.

8.6.1 Oil change

Burning hazard if touched! At oil temperatures above 60 °C (60,00 °C) wear appropriate PPE!

When disposing of used oil, legal requirements must be met. The proprietor of the machine is responsible for proper disposal!

Every 5000 operating hours an oil sample should be taken and, depending on the analysis, an oil change be carried out. This assumes a maximum operating temperature of 60 °C (140 °F) (with ServoPower (Option) 50°C (122°F)) and regular oil fi lter changes. To establish the oil change interval suitable for the local operating conditions it is recommended to test the oil at fi rst after shorter intervals (e.g. monthly).

The test sample must be taken from the pressure line at operating temperature.

Regardless of the usage the hydraulic oil should be changed after one year at the latest. If the oil is not changed or is changed too late the machine will be unreliable and damaged, especially as a result of abrasive contaminants in the hydraulic oil which can not be removed by the fi lter.


ATTENTIONLeaked oil is always contaminated and must never be put back into the hydraulic tank!

Ensure greatest cleanliness! The fi ller on the hydraulic tank and the fi ller and screw plugs on the transport and storage tanks must be thoroughly cleaned before use. The new hydraulic oil must be checked for ingress of water. If hydraulic oil becomes contaminated with water it will be of inferior quality and must not be used any further.

The oil change should be carried out immediately after the end of a production run on the machine. This ensures that the oil is at operating temperature and viscosity (45 °C to 50 °C / 113 °F to 122 °F) (with ServoPower (Option) 35°C and 40°C (95°F and 104°F)) and particles are still in suspension so that they can be pumped out with the oil.

1 Clean the fi ller screws and the screw plugs on transport and storage containers.

2 Check the hydraulic oil grade; see "Oil quality"

3 Prefi lter the hydraulic oil through a mobile fi ltration unit.


5 Switch off main isolator and secure against accidental reconnection.

6 Clean the area round the venting fi lter.

7 Unscrew the venting fi lter lock and remove the complete venting fi lter from the pipe socket.

8 Empty hydraulic tank with a pump unit via the pipe socket. The hose must reach to the bottom of the tank.

9 Remove the tank cover; clean the hydraulic tank

ATTENTIONIf the tank is fi lled above the maximum level, hydraulic oil will come out of the venting fi lter!

The new hydraulic oil may only be fi lled through the air venting fi lters. This must be done through a separate fi ltration unit (fi lter mesh size 3 μm / 118.11 μinch), which guarantees a cleanliness class of 15/12 acc. to ISO 4406 (Class 6 acc. to NAS 1638 or CETOP RP 70H) Experience has shown that even new oil is not this clean.

ATTENTIONOnly use new hydraulic oil and under no circumstances mix different grades or different makes with each other. The type of oil should not be changed without compelling reasons. If this is the case, the system must be fl ushed out with the new oil fi rst!


To avoid mixing oils it is recommended to mark the oil tank and fi llers with the oil type.

1 Fill the hydraulic tank to the maximum mark with a mobile fi ltration unit

The max. fi lling level is shown by the upper marking on the oil level indicator.

2 Place the venting fi lter on the pipe socket again.

3 Reconnect the bypass fi lter unit, if fi tted

ATTENTIONBefore switching on the machine, the hydraulic oil should be allowed to stand for approx. 1 hour to let the air trapped during fi lling escape!

8.6.2 DeaerationAfter fi lling the hydraulic tank air must be bled from the hydraulic system.

• Press the "Hydraulic start" key to switch on the hydraulics

• Press the "Setting" key.

• Drive the clamping platen, injection unit and injection cylinder several times to and fro over their whole stroke.

Bleeding is carried out effectively when no foam appears in the hydraulic tank, movements are smooth and there are no strange noises.

The oil level should be checked after bleeding and topped up if necessary. Care must be taken to use the same oil type.

8.6.3 Checking the oil levelContinuous (daily) monitoring of the oil level is required as a drop in the oil level below the marked minimum volume may lead to an increase in operating temperature, undissolved air and pump failure from cavitation.


8.6.4 Oil change Axial bearing For injection unit 8800 only and if the "Servo-motor" option is installed

The oil should be changed every 5000 operating hours.

1 Turn off the main switch and secure against accidental reconnection.

2 Dismount the injection cylinder guarding (screw out the screws).

3 Thoroughly clean the area around the vented fi ller cap.

4 Undo the vented fi ller cap slightly to allow air to enter, do not unscrew entirely.

5 Undo fi tting underneath and drain the gear oil into a suitable container.

6 Screw in the screw connection underneath.

7 Unscrew the vented fi ller cap (1).

8 Pour in new gear oil.

9 Screw in the vented fi ller cap (1).

10 Mount injection cylinder guarding.

ATTENTIONThe oil level should be checked daily. The axial bearing should be checked daily for leaks and damage to the shaft seals.

8.6.5 Hydraulic fi lter Pressure fi lters are installed in front of components which require extra protection. The pressure fi lter has a contamination indicator which sends an error message to the screen if it is triggered.

At the fi rst possible pause in production (e.g. shift change) the fi lter must be replaced. If there are no spare fi lters available one must be ordered immediately. The article number can be found in the chapter "Spare parts / Plans".

In principle the fi lter element should be changed at the same time as the oil. If the above error message or the oil analysis indicates an early oil change, then the oil fi lter should be changed early too.

The greatest cleanliness must be maintained. The contamination indicator is suppressed at low temperatures; i.e. if the oil temperature is below 27 °C (80.6 °F) the switch does not function.


8.6.6 Changing the fi lter element

• Switch off the machine and wait for complete pressure loss.

If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury!

Burning hazard if touched! At oil temperatures above 60 °C (140 °F) wear appropriate PPE!

• Unscrew fi lter housing (1). Run hydraulic oil into a suitable container.

• Remove fi lter element (2); inspect the mesh surfaces for contamination and large particles. These can be an indication of damaged hydraulic components.

• Dispose of fi lter element (2)

• Before fi tting the fi lter element, check that the type designation is the same as that of the fi lter element removed.

ATTENTIONNever clean or reuse a fi lter element!

• Replace the fi lter element. The fi lter element can not be cleaned. Any attempt to clean the fi lter element can damage the fi lter material which will then allow contaminated oil to reach the clean side of the fi lter element.

• Clean the fi lter housing (1) (inside) with a suitable agent (e.g. white spirit, paraffi n/kerosene) and make sure no dirt gets into the clean side.

4

1

2

3


• Inspect the fi lter unit for mechanical damage, especially to sealing faces and seals. Renew damaged parts. Check O-rings (3 + 4) and change if damaged.

ATTENTIONIf damaged components are not replaced and if the fi lter is not kept in perfect condition, other hydraulic components may be damaged or fail!

• Lightly oil the threads and sealing faces of the fi lter and the O-ring (3) of the fi lter element (2) with clean liquid

• Mount the fi lter element on its location.

• Screw the fi lter housing (1) right in.

• Start the hydraulic system under pressure and check the fi lter for leaks. If a leak is found then the corresponding O-ring should be renewed.


8.6.7 Venting fi lterVenting fi lters allow fi ltered air to pass in and out of the oil tank as the oil level changes. Its effectiveness depends upon the environment, but it should be checked and if necessary the element renewed after 2500 operating hours at the latest, paying the greatest attention to cleanliness.

Change the venting fi lter hydraulic tank

• Switch off the machine and wait for complete pressure loss.

• Remove guarding if necessary.

• Remove hexagon nut (1) (DIN 934 M10 SW 17) and washer.

• Lift off cover (2)

• Remove element (3) and mount new element

• Put cover back on

• Put on washer and Skt. Screw on the nut

3

1

2

HM_1034.BMP


8.6.8 LeaksObserve any leaks in the hydraulic system and remedy them by resealing or tightening the screw connections.

Damaged hydraulic hoses and hose assemblies must be renewed at once, please refer to the chapter "Hose assemblies".

Regular checks of the hydraulic fi ttings, hose asemblies, cylinders, valves, pump(s) etc. must be carried out every 160 running hours.

8.6.9 Oil coolerAlthough the oil cooler may be considered maintenance free, it is recommended to give it some preventive maintenance every 20,000 operating hours.

Contaminated water must be fi ltered and if scale is present the cooling lines must be descaled.

See also "Water quality".


8.7 Pressure vessel

Work at pressure vessels may only be carried out by specially trained personnel!Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released!Risk of explosion! Only use nitrogen "N2" as gas!

Before starting up the machine the nitrogen pressure within the pressure vessel (option) must be checked. In case the nitrogen pressure falls short of the indicated value (see name plate or hydraulic plan), nitrogen has to be refi lled.

Pressure vessels are subject to the safety regulations applicable at the place of use. Before starting up the machine, they have to be accepted by the technical standards organisation (e.g. TÜV) responsible in the proprietor’s region.

The proprietor of pressure vessels is responsible for ensuring the proper condition, operation and monitoring.

Neither welding nor soldering nor any mechanical processing may be performed on the pressure vessels. Improper repairs can cause severe accidents and may only be carried out by authorised customer service personnel.

8.7.1 Checking the nitrogen pressureCheck the nitrogen pressure before and during operation as follows:

1 At least once within the fi rst 40 operating hours. Major losses in nitrogen will immediately be detected and be compensated.

2 In case no losses have been detected during the fi rst inspection, the next inspection is to be carried out after 500 operating hours.

3 After this inspection further inspections may be carried out at an interval of 1000 operating hours.

ATTENTIONThe nitrogen pressure changes temperature dependently. For this reason, inspections should always be carried out under equal temperature conditions. After fi lling or discharging nitrogen please wait 5 minutes approx. until the temperature has been balanced. Check the nitrogen pressure afterwards!During each check nitrogen will escape through the fi lling unit. This will reduce the nitrogen pressure, especially in case of small pressure vessels!The pressure within the mobile nitrogen cylinder (for fi lling the pressure vessel) may not exceed the maximum permissible operating pressure of the machine’s pressure vessel or the pressure gauge. Otherwise a pressure reducer has to be inserted between the mobile pressure cylinder and the fi ller!

Please keep all certifi cates in a safe place!

When demanding certfi cates later on, please state the contents, the factory number and the year of manufacture of the vessel. These data is embossed on both ends of the vessel.


8.7.2 Replenishing, reducing and testing the nitrogen pressureThe fi lling and testing unit is not included in the standard delivery.

1 Mount the pressure gauge as described in "Checking the hydraulic pressure".

2 Switch off the machine at the main switch.

3 Wait for the pressure of the hydraulic oil within the pressure vessel to be reduced (until the pressure gauge indicates 0 bar / psi)

4 Unscrew the covering cap(s) of the gas fi lling valve.

5 Screw the fi ller unit to the gas fi lling valve.

6 Check whether the venting valve of the fi ller unit is closed.

7 Screw the hose assembly’s connecting piece to the nitrogen bottle.

8 Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly fl owing into the pressure vessel (for the fi lling pressure please refer to the hydraulic plan or the respective label).

9 Close the shut-off valve after reaching the desired nitrogen pressure.

10 Use the venting valve to close the fi lling hose.

11 Press the button of the fi ller unit, release it and read off the nitrogen pressure at the pressure gauge.

12 In case the nitrogen pressure is too high, carefully press the pressure pin after opening the venting valve to reduce the pressure.

Steps 7, 8 and 9 will be omitted when reducing or checking the pressure.

1 - Connection for the nitrogen cylin-der (Right-hand thread W24.32x 1 1/4")

2 - Non-return valve (valve insert) 3 - Button 4 - Pressure pin 5 - Valve gate 6 - Venting valve 7 - Union nut 8 - Seal element 9 - Connection piece (SAE 7/8" -

14UNF -2B) 10 - Gas fi lling valve 11 - Bubble accumulator

2 3

4

5

7

6

11

8

9

10

1


8.7.3 Checking the hydraulic pressure

Work at pressure vessels may only be carried out by specially trained personnel!Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released!Risk of explosion! Only use nitrogen "N2" as gas!

• Screw a pressure gauge connection-hose assembly, which is not included in the standard delivery, to the fi tting of a pressure gauge.

• Clean the surroundings of the miniature measuring connection at the hydraulic block of the pressure vessel.

• Remove the sealing cap of the miniature measuring connection.

• Screw in the fi tting of the pressure gauge connection-hose assembly.

• You can only retrieve the hydraulic pressure within the pressure vessel from the pressure gauge.

8.8 Hose assembliesThe safety regulations are laid down in DIN 20066 Parts 4 and 5 as well as in EN 201. They contain regulations on the testing, replacement and storage of hydraulic hose assemblies.

The proprietor of the machine has a duty to ensure that hose assemblies are replaced at the appropriate intervals, even if no technical shortcoming is apparent in the hose assembly.

8.8.1 Service lifeEven when properly stored and under allowed stresses, hoses and hose assemblies are subject to natural ageing. Their service life is therefore limited.

Improper storage, physical damage and non-approved application are the most common causes of failure.

The service life (including storage time) for hoses and hose assemblies must not be exceeded. The date of manufacture is permanently marked on every hose and hose assembly.

The hose assemblies have to be replaced after 20000 operating hours at the latest


Hoses which have already been in service as part of a hose assembly may not be reused as they no longer conform to the requirements of DIN 20066.

If a hose is reused, then the liability lies with the person who fi ts the hose assembly.

Only hose assemblies with swaged-on stand-pipe ends can be reused. The length of a hose assembly is defi ned as shown in the following diagram.

8.8.2 Inspection criteriaThe serviceability must be verifi ed by a hydraulics expert every 1000 operating hours.

Hose assemblies must be replaced at once if any of the following criteria are established on inspection:

• Damage to the outer sheath which reaches the reinforcement (e.g. chafi ng, cuts or cracks).

• Embrittlement of the outer sheath (cracking of hose material).

• Deformation not consistent with the natural form of the hose assembly, in either the pressurised or the relaxed condition, or in fl exure, e.g. delamination or blistering (see also DIN 20066 Part 4)

• Permeability or porosity.

• Damage or deformation of the hose fi tting (affecting sealing); trivial surface damage is not a reason for replacement.

• Movement of the hose from the ferrule.

• Corrosion of the fi tting affecting function or strength.

• Assembly guidelines not followed (DIN 20066 Part 4).

• Storage or service periods elapsed.

Length including standpipe ends


8.9 Hydraulic accessoriesIf the machine’s hydraulic system is equipped at the customer’s wish with additional components, like bypass fi ltration units, then the corresponding operating instructions in the "Accessories" section of this technical documentation must fi rst be read, in its entirety, without fail.

If the hydraulic system of the machine is not relieved of pressure before fi tting or removing hydraulic component it may empty explosively with the risk of damage and injury!

Before operating the machine, its safety regulations and the operating instructions of the hydraulic accessory in question must be observed without fail!

The mounting and dismounting, setting, commissioning and repair of hydraulic accessories may only be carried out by authorised personnel!

8.10 Lubrication

8.10.1 Manual grease lubrication Before greasing, the machine must be secured against accidental reconnection!

The lubricating nipples should be treated every 500 operating hours with an ordinary grease gun (may be pneumatic) for DIN 71412 - type lubricating nipples.

The grade of grease can be seen in the "Hydraulic oil and lubricant table".

8.10.2 Three phase motorThe three-phase motor bearings have to be cleaned and regreased every 20000 running hours.

The grade of grease can be seen in the "Hydraulic oil and lubricant table".

8.10.3 Screw drive

Before checking, the machine must be secured against accidental reconnection!

The axial bearing is arranged so that the leakage line from the hydraulic motor lubricates it. No maintenance is thus necessary in this case.

The oil level must be checked before the fi rst start-up and, if necessary, oil must be fi lled in or refi lled in the "Axial bearing" of injection unit 8800 and if the servo-motor option is installed, refer to paragraph 8.6.4.


8.10.4 Corrosion protectionAll bare parts (tie-bars, piston rods, guide rails), where no movement takes place should be sprayed every 500 operating hours with a corrosion inhibiting oil.

8.11 Water system

ATTENTIONWhen using water piping note the corrosion stability of metallic materials against water in accordance with DIN 50930!

Water piping and the respective fi ttings are to be weekly checked for corrosion and leakages by a skilled technician.


Burning hazard if touched! At water temperatures above 50 °C (50.00°C) wear appropriate PPE!

8.11.1 Water qualityIf there are deviations from the following guidelines, please contact our technical customer service or one of our subsidiaries. The addresses can be found in the "Customer service" chapter.

pH value: 6,5 - 9

Water hardness: < 1,8 mmol / l (681 ppm / gal)

Solids: < 0,03 ‰ (30 ppm)

Filter mesh: < 100 μm (0.004 inch)

In the relation of solids content to water hardness, it should be noted that the harder the cooling water is the lower the solids content has to be. If the level of suspended matter is over 0,03 ‰ (30 ppm), a water fi lter with a mesh size < 100 μm (0.004 inch) must be fi tted before the water system.

8.11.2 Closed cooling circuit systemIt is recommended to add a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from Henkel).

We recommend ethylene glycol type 420 as an antifreeze (60 % water and 40 % ethylene glycol). This is suitable for a temperature range down to -30 °C (-22 °F) and is also a corrosion inhibitor.


8.11.3 Hydraulic oil temperatureCheck the hydraulic oil temperature in the oil tank daily. The machine is most effi cient at an oil temperature between 45 °C and 50 °C (113 °F and 122 °F) (with ServoPower (Option) 35°C and 40°C (95°F and 104°F)(.

The current hydraulic oil temperature will be displayed on the screen (B2 = in the actual value fi eld "T12" on page 2 of the "Temperature control zones" screen page / B4 = "Barrel temperatures 1" screen page).

8.11.4 Oil coolerEvery 20000 running hours, the cooling tubes should be fl ushed out with a descaling solution to remove any limescale deposits (max. 16 bar / 232 psi).

8.11.5 Cooling water fl ow governor• Check cooling water fl ow governor daily for fl ow and leaks.

• Likewise check the cooling water connections and hoses for fl ow (no kinked hoses) and leaks.

• The sight glasses may need cleaning if the coolant is dirty.

• The consumers, moulds, throat cooling, etc. should be fl ushed out every 20000 operating hours with a descaling solution.


8.12 Electrical equipment

For all work involving fi tting, removal, modifi cation and maintenance, the legal rules and regulations and the safety instructions in the "Safety" chapter must be observed without fail!Work on electrical components may only be carried out by a qualifi ed electrician!

8.12.1 Filter matsThe fi lter mats can be cleaned as follows:

• Washing in water (up to approx. 40 °C / 104 °F, with mild detergent if desired). Shaking, vacuuming or blowing out with air is also possible.

• If the dust is greasy the fi lter mat must be washed out in water with a grease dispersant additive.

8.12.2 Buffer batteryThe control unit is protected from data loss by a buffer battery. When the error message "Buffer battery fl at" appears, the battery has to be replaced. The battery must be replaced for the fi rst time after 5 years at the latest, then every 3 years.

Battery change (type: lithium battery 3 V / 950 mA):

ATTENTIONData loss without buffering! For security purposes, a copy of the service and tool record has to be fi led on fl oppy disk before changing the battery.

1 Switch off the main switch.

After changing the battery, the main switch has to be switched on again within 30 sec. so that no data are lost

2 Carry out an electrostatic discharge at the top hat rail or at the earth connection (do not reach into the power supply)

3 Open the battery compartment by means of a screw driver. Position the screw driver in the slot and open the compartment by lifting

4 Pull the battery out of the support by pulling at the battery compartment cover


5 Take out the lithium battery (do not touch the battery with pliers or uninsulated tweezers -> short circuit). Only touch the battery on the front side with your hands. Insulated tweezers can also be used to take out the battery.

6 Position the new battery with the correct polarity. The removal strip must be located underneath the battery, otherwise the battery cannot be extracted

7 Close the cover of the lithium battery

8 Switch on the main switch

When disposing of batteries, the legal requirements must be met. The proprietor of the machine is responsible for proper disposal!


8.13 Pneumatic system

If the pneumatic system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury!

8.13.1 UNIFEED material feeder

The secondary fi lter (3) of UNIFEED material feeder (option) should be cleaned as necessary and in any case inspected at least once a week, depending on the amount of dust. Its service life is limited and it should be renewed at the fi rst sign of loose fi bres (by simply removing it from its holder).

The primary fi lter (2) is automatically cleaned by compressed air after every conveying cycle. If it becomes clogged it is cleaned as follows:

1 Turn off air supply.

2 Remove knurled nuts (4).

3 Lift off cover (1).

4 Clean and insert primary fi lter (2) again.

5 Insert cover.

6 Do up knurled nuts (4).

When fi tting the fi lter care must be taken to position the fi lter O-ring properly in the groove provided.

1234


8.13.2 Air supply unit The oil level of the air supply unit (option) should be checked every 8 operating hours and topped up if necessary. The oil grade is given in the "Hydraulic oils and lubricants table".

8.13.3 Filter cartridgeThe interval for cleaning depends on the amount of dirt in the air. An interval of 500 running hours may be taken as a guide.

• Turn off air supply.

• Unscrew fi lter cartridge.

8.13.4 Mechanical scotchThe mechanical scotch (option) will only work if all components are in faultless condition and moving parts have free movement. Care must be taken that the face of the scotch (or "fl ag"), against which a tooth of the scotch-bar presses when it is activated, shows no signifi cant wear. Malfunction of the mechanical scotch can be avoided if the hardened plate is turned over or renewed in good time.

EWAGB0TB0814TW Chapter 9 - 1

9 Spare parts / PlansThe chapter Spares / Plans contains parts list, plans and drawings representing the complete range of the machine, broken down into assemblies. There is an assembly drawing for every 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 spare parts order. In addition please state the Identifi cation number (ID No.), the Designation and the desired Quantity.

When ordering, please contact the Wittmann Battenfeld GmbH agency responsible for you or contact Wittmann Battenfeld GmbH directly.

EWAGB0TB0814TWChapter 9 - 2

EWAGB0UB0814TW Chapter 10 - 1

10 Special descriptions

EWAGB0UB0814TWChapter 10 - 2

product line smartpower b6

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