Betriebsanleitung Ferromatik Milacron Maschinenbau GmbH Riegeler Str. 4, D-79364 Malterdingen Tel. ++49-7644-78-0, Fax ++49-7644-6885 email: [email protected], http://www.ferromatik.com Operating instructions Manuel d'instructions Manual de instrucciones Manual de instruções Istruzioni di servizio Machinehandboek Betjeningsvejledning Driftsinstruktion Käyttöohje Instrukcja obsługi Návod k obsluze Manual di operare Kullan Im kIlavuzu Type K-TEC 40 - K-TEC 155 Machine No. Year of construction 2004 Date 10.05.2004
Transcript
Betriebsanleitung
FerromatikRiegeler STel. ++4email: fm_
Milacron Maschinenbau GmbH
Operating instructionsManuel d'instructionsManual de instruccionesManual de instruçõesIstruzioni di servizioMachinehandboekBetjeningsvejledningDriftsinstruktionKäyttöohjeInstrukcja obsługiNávod k obsluzeManual di operareKullan Im kIlavuzu
Type K-TEC 40 - K-TEC 155
Machine No.
Year of construction
2004
Date 10.05.2004
tr. 4, D-79364 Malterdingen9-7644-78-0, Fax [email protected], http://www.ferromatik.com
Table of contents
TABLE OF CONTENTS
1 Before you begin ... ................................................................................................. 1-11.1 Preliminary remarks ............................................................................................................... 1-11.2 Warning symbols and instructions in the operating manual and
on the machine 1-11.2.1 Warning instructions of danger to humans................................................................. 1-11.2.2 Symbols in the operating manual ............................................................................... 1-21.2.3 Warning instructions and symbols on the machine .................................................... 1-3
3.1.1 Responsibility ............................................................................................................. 3-13.1.2 Conformity .................................................................................................................. 3-13.1.3 Danger analysis and risk assessment........................................................................ 3-13.1.4 Layout of safety instructions....................................................................................... 3-1
3.2 Structural safety of the plant................................................................................................. 3-33.3 Safety devices......................................................................................................................... 3-3
3.4 Residual risk ........................................................................................................................... 3-83.5 Responsibility of user ............................................................................................................ 3-9
3.6 List of safety hazards........................................................................................................... 3-133.6.1 Vapours hazardous to health ................................................................................... 3-133.6.2 Unintentional material spray from nozzle ................................................................. 3-133.6.3 Hydraulics................................................................................................................. 3-133.6.4 Gas operated/filled systems..................................................................................... 3-143.6.5 Electrical systems..................................................................................................... 3-143.6.6 Control...................................................................................................................... 3-153.6.7 Heated machine parts .............................................................................................. 3-153.6.8 Other machine parts................................................................................................. 3-15
3.7 In case of an emergency...................................................................................................... 3-163.7.1 In case of fire............................................................................................................ 3-16
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3.8 Safety instructions for machine operation......................................................................... 3-173.8.1 Normal operation...................................................................................................... 3-17
3.9 Setting, repair and maintenance work................................................................................ 3-18
4 Description and function ........................................................................................ 4-14.1 Clamping unit.......................................................................................................................... 4-2
5 Installation ............................................................................................................... 5-15.1 Technical data for machine location..................................................................................... 5-1
5.1.1 Noise emission value ................................................................................................. 5-15.1.2 Permissible ambient conditions.................................................................................. 5-1
5.2 Installing the machine ............................................................................................................ 5-25.2.1 Preparation for delivery of machine............................................................................ 5-25.2.2 Preparation for transport within company's premises................................................. 5-35.2.3 Transporting the machine........................................................................................... 5-35.2.4 Reporting transport damage....................................................................................... 5-75.2.5 Erecting the electric cabinet ....................................................................................... 5-85.2.6 Installation with crane* ............................................................................................... 5-9
5.3 Aligning the machine ........................................................................................................... 5-105.3.1 Aligning the base...................................................................................................... 5-105.3.2 Aligning injection unit................................................................................................ 5-165.3.3 Checking the alignment of the nozzle head in the stationary
mould clamping platen ............................................................................................. 5-175.3.4 Aligning nozzle on sprue bushing in the mould ........................................................ 5-175.3.5 Checking mould clamping platen parallelism ........................................................... 5-20
5.4 Cleaning, filling and connecting the machine ................................................................... 5-215.4.1 Cleaning the machine after delivery ......................................................................... 5-215.4.2 Fitting the material hopper........................................................................................ 5-215.4.3 Filling with hydraulic oil............................................................................................. 5-225.4.4 Cooling water connection ......................................................................................... 5-255.4.5 Electrical connection ................................................................................................ 5-29
5.5 Disassembly of injection moulding machine..................................................................... 5-30
6 Start up procedure .................................................................................................. 6-16.1 Switching on machine............................................................................................................ 6-1
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6.2 Rotational direction of the electric motor ............................................................................ 6-16.2.1 Checking function and rotation of motor..................................................................... 6-16.2.2 Setting rotational direction of motor............................................................................ 6-36.2.3 Checking electric motor and hydraulic lines ............................................................... 6-4
7.7 Setting plasticizing process ................................................................................................ 7-717.7.1 Basis......................................................................................................................... 7-717.7.2 Stroke or volume dependent parameters ................................................................. 7-717.7.3 Screw r.p.m. ............................................................................................................. 7-737.7.4 Back pressure .......................................................................................................... 7-747.7.5 Backpressure relief or screw end position control (only for S-version)..................... 7-757.7.6 Hydraulic shut-off nozzle (option) ............................................................................. 7-767.7.7 Plasticizing delay...................................................................................................... 7-787.7.8 Intrusion.................................................................................................................... 7-787.7.9 Cooling time ............................................................................................................. 7-78
7.8 Setting the injection process............................................................................................... 7-797.8.1 Number of injection stages....................................................................................... 7-797.8.2 Injection pressure ..................................................................................................... 7-807.8.3 Injection speed ......................................................................................................... 7-807.8.4 Injection time, time-dependent switchover ............................................................... 7-807.8.5 Switchover pressure, pressure-dependent switchover............................................. 7-817.8.6 Switchover point, stroke-dependent switchover ....................................................... 7-817.8.7 Mould cavity pressure dependent switchover (requires optional equipment)........... 7-827.8.8 Two-colour injection ................................................................................................. 7-84
7.9 Setting machine monitoring ................................................................................................ 7-877.9.1 Trend diagram .......................................................................................................... 7-887.9.2 Time analysis ........................................................................................................... 7-937.9.3 Production data ........................................................................................................ 7-947.9.4 Recording of process data ....................................................................................... 7-997.9.5 Cycle time monitoring............................................................................................. 7-1037.9.6 Plasticizing time monitoring.................................................................................... 7-1057.9.7 Plasticizing stroke monitoring................................................................................. 7-1067.9.8 Injection parameter monitoring............................................................................... 7-1077.9.9 Automatic machine shutdown ................................................................................ 7-108
7.10 Freely composable screen pages ..................................................................................... 7-1097.10.1 Composing pages .................................................................................................. 7-1097.10.2 Changing user compiled pages.............................................................................. 7-1107.10.3 Required value entries on user compiled pages .................................................... 7-110
7.11 Freely writeable screen pages........................................................................................... 7-1117.12 Configurable digital inputs and outputs........................................................................... 7-112
7.12.1 Configurable digital inputs ...................................................................................... 7-1127.12.2 Configurable digital outputs.................................................................................... 7-1137.12.3 Configurable analogue outputs (option) ................................................................. 7-115
7.13 Standard graphics .............................................................................................................. 7-1177.13.1 Setting of standard graphics................................................................................... 7-1177.13.2 Display of the standard graphics ............................................................................ 7-120
7.14 Working with the background set of data ........................................................................ 7-1227.14.1 Optimizing the foreground data set in the background........................................... 7-1227.14.2 Preparing a new data set in the background.......................................................... 7-1237.14.3 Comparing foreground data set and background data set ..................................... 7-124
7.15 Storing and reading of parameter sets............................................................................. 7-1257.15.1 Formatting data carrier ........................................................................................... 7-1257.15.2 Storing data set on disk.......................................................................................... 7-1287.15.3 Reading out specific data sets from data disk........................................................ 7-131
7.17 Preparing for operation...................................................................................................... 7-1407.17.1 Prerequisite ............................................................................................................ 7-1407.17.2 Short inspection before start of work...................................................................... 7-1407.17.3 Fill hopper............................................................................................................... 7-1427.17.4 Switching on cooling water supply ......................................................................... 7-1447.17.5 Switching on machine ............................................................................................ 7-1467.17.6 Setting oil preheating.............................................................................................. 7-1497.17.7 Activating central lubrication (option) ..................................................................... 7-1517.17.8 Checking by-pass oil filtration and oil cooling......................................................... 7-151
7.18 Starting production ............................................................................................................ 7-1527.18.1 Reaching processing temperature ......................................................................... 7-1527.18.2 Plasticizing in manual mode and purging screw cylinder ....................................... 7-1527.18.3 Position screw for production ................................................................................. 7-1537.18.4 Running a test cycle ............................................................................................... 7-1547.18.5 Parameter set for production start (option)............................................................. 7-155
7.19 Material or colour change.................................................................................................. 7-1567.20 Work breaks ........................................................................................................................ 7-1577.21 Switching machine off ....................................................................................................... 7-158
7.21.1 Emptying hopper .................................................................................................... 7-1587.21.2 Purging screw cylinder ........................................................................................... 7-1587.21.3 Moving screw into forward position ........................................................................ 7-1587.21.4 Switch off cylinder heating...................................................................................... 7-1597.21.5 Switching off hydraulic unit..................................................................................... 7-1597.21.6 Allow screw cylinder to cool ................................................................................... 7-1597.21.7 Switching off main switch ....................................................................................... 7-1597.21.8 Shutting off cooling water supply............................................................................ 7-1607.21.9 Shutting down the machine immediately in an emergency with
the emergency-off function and restarting.............................................................. 7-1607.22 Weekday timer (option)...................................................................................................... 7-1617.23 Process graphics (option) ................................................................................................. 7-163
7.23.1 Setting process graphics ........................................................................................ 7-1667.23.2 Required and actual comparison and tolerance monitoring ................................... 7-1717.23.3 Calculating injection work....................................................................................... 7-174
7.24 Statistical process control (option) .................................................................................. 7-1777.24.1 Setting the SPC control charts ............................................................................... 7-1797.24.2 Calculation and evaluation ..................................................................................... 7-182
7.25 Ejector and core movement while safety gate is open via key switch (option) ........... 7-1877.26 MONOSANDWICH process (option) ................................................................................. 7-1887.27 AIRPRESS gas injection technique (GIT) from Ferromatik Milacron (option) .............. 7-192
8 Elimination of faults ................................................................................................ 8-18.1 Step list.................................................................................................................................... 8-18.2 Fault diagnosis ....................................................................................................................... 8-68.3 Source of faults when installing mould.............................................................................. 8-108.4 Source of faults during injection ........................................................................................ 8-11
9 Repairs and maintenance ....................................................................................... 9-19.1 Working on the injection unit ................................................................................................ 9-3
9.1.1 Swiveling injection unit out/in ..................................................................................... 9-39.1.2 Swivelling injection unit out
(injection unit of international size 970, optional on K-TEC 155)................................ 9-79.1.3 Changing nozzle body (flanged nozzle body) .......................................................... 9-109.1.4 Changing nozzle body (screw-in nozzle body)......................................................... 9-149.1.5 Changing screw and screw tip ................................................................................. 9-179.1.6 Screw cylinder change ............................................................................................. 9-22
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9.2 Working on clamping unit.................................................................................................... 9-279.2.1 Replacing the piston rod seals; replacing the pressure bolts ................................... 9-279.2.2 Automatic central lubrication (option) ....................................................................... 9-28
9.3 Working on the hydraulic system ....................................................................................... 9-299.3.1 Safety measures while working on the hydraulic system ......................................... 9-299.3.2 Storing and disposing of hydraulic oil ....................................................................... 9-299.3.3 Instructions for exchanging hydraulic components .................................................. 9-309.3.4 Recording of work on the hydraulic system.............................................................. 9-309.3.5 Oil maintenance procedure ...................................................................................... 9-319.3.6 Changing plate heat exchanger ............................................................................... 9-38
9.4 Working on the pressure accumulator plant ..................................................................... 9-409.4.1 General information on the accumulator system...................................................... 9-409.4.2 Work on the accumulator ......................................................................................... 9-429.4.3 Testing of accumulator plant by safety standards authority ..................................... 9-459.4.4 Checking the nitrogen accumulator .......................................................................... 9-47
9.5 Safety rules for hydraulic hoses ......................................................................................... 9-489.6 Check list for recurring inspection and maintenance work ............................................. 9-499.7 Daily checks .......................................................................................................................... 9-51
9.7.1 Short inspection before start of work ........................................................................ 9-519.8 Maintenance work weekly and during mould change....................................................... 9-52
9.8.1 Checking safety devices........................................................................................... 9-529.8.2 Checking nozzle alignment ...................................................................................... 9-539.8.3 Checking feedthroat cooling..................................................................................... 9-539.8.4 Checking cooling of electric screw drive (option) ..................................................... 9-549.8.5 Checking hydraulic oil level ...................................................................................... 9-559.8.6 Checking hydraulic oil temperature .......................................................................... 9-569.8.7 Lubricating the rods.................................................................................................. 9-579.8.8 Checking the bearing of the moving mould clamping platen.................................... 9-579.8.9 Greasing guide shoes (only K-TEC 155).................................................................. 9-589.8.10 Checking grease level of the automatic central lubrication system.......................... 9-58
9.9 Maintenance work monthly or every 200 operating hours ............................................... 9-599.9.1 Cleaning ventilation filter of the electrical cabinet .................................................... 9-599.9.2 Cleaning the ventilation filter of the IQT control unit................................................. 9-609.9.3 Cleaning disk drive ................................................................................................... 9-619.9.4 Initial oil maintenance measures .............................................................................. 9-629.9.5 Replacing tank ventilation filter................................................................................. 9-629.9.6 Checking ventilation of the motors ........................................................................... 9-649.9.7 Inspecting pumps ..................................................................................................... 9-659.9.8 Plate heat exchanger cooling effect ......................................................................... 9-669.9.9 Checking hydraulic pump for leakages .................................................................... 9-669.9.10 Checking the set values of the cooling water manifold ............................................ 9-679.9.11 Checking modules and electrical switching elements of the control......................... 9-689.9.12 Checking terminal and plug connections.................................................................. 9-689.9.13 Checking the nitrogen pressure of the accumulator system (only S-version) .......... 9-69
9.10 Maintenance work quarterly or every 1000 operating hours............................................ 9-709.10.1 Checking seating of thermocouples on the screw cylinder....................................... 9-709.10.2 Retighten retaining screws of the screw................................................................... 9-719.10.3 Checking the nitrogen pressure of the accumulator system (only S-version) .......... 9-71
9.11 Maintenance work yearly or every 5000 operating hours................................................. 9-729.11.1 Checking system pressures ..................................................................................... 9-729.11.2 Checking the lead seals on the safety valves (only S-version) ................................ 9-729.11.3 Checking hoses and connections............................................................................. 9-739.11.4 Checking machine level ........................................................................................... 9-739.11.5 Checking linear guides ............................................................................................. 9-749.11.6 Lubricating linear guides .......................................................................................... 9-749.11.7 Checking stroke measuring systems, limit switches and cables for proper
seating and tighness ................................................................................................ 9-759.11.8 Checking screw release ........................................................................................... 9-77
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9.11.9 Cleaning cooling water manifold .............................................................................. 9-789.11.10 Motor maintenance according to specifications on motor identification plate .......... 9-799.11.11 Cleaning IQT operator terminal and screen ............................................................. 9-799.11.12 Adjustment according to setting instructions ............................................................ 9-799.11.13 Checking platen parallelism ..................................................................................... 9-799.11.14 Checking tightness of strain rod nut ......................................................................... 9-809.11.15 Checking the nitrogen pressure of the accumulator system (only S-version) .......... 9-80
9.12 Maintenance work every 7500 operating hours................................................................. 9-819.12.1 Oil change, tank cleaning, oil level monitor check, ventilation filter replacement..... 9-81
9.13 Maintenance work every 3 years......................................................................................... 9-879.13.1 Changing the buffer battery of the control ................................................................ 9-879.13.2 Replacing the back-up battery of the IQT control..................................................... 9-88
9.14 Maintenance work every 6 years......................................................................................... 9-899.14.1 Replacing high pressure hose lines ......................................................................... 9-899.14.2 Basic motor cleaning ................................................................................................ 9-89
9.15 Maintenance work every 10 years....................................................................................... 9-909.15.1 Testing by the responsible safety authority .............................................................. 9-90
9.16 Customer service ................................................................................................................. 9-90
10 Technical data ....................................................................................................... 10-110.1 Instructions on the operation of the plate heat exchanger .............................................. 10-8
10.1.1 Construction and function......................................................................................... 10-810.1.2 Start up procedure.................................................................................................... 10-810.1.3 Notes on cooling water............................................................................................. 10-9
10.2 Torque values ..................................................................................................................... 10-1310.2.1 Torque values for cylinder screws DIN 912 on Ferromatik Milacron
subassemblies........................................................................................................ 10-1310.2.2 Torque values for Bosch hydraulic components .................................................... 10-1410.2.3 Torque values of nuts for studs on injection and traverse cylinders....................... 10-1410.2.4 Torque value for tank cover nuts............................................................................ 10-14
10.3 Lubricant recommendations ............................................................................................. 10-1510.3.1 Hydraulic oils .......................................................................................................... 10-1510.3.2 Lubrication of the strain rods and guide rods ......................................................... 10-1610.3.3 Lubrication of the electric motor ............................................................................. 10-1610.3.4 Lubrication of linear guides of injection unit ........................................................... 10-1610.3.5 Greasing the mould clamping platen guide shoes (only for K-TEC 155) ............... 10-1710.3.6 Lubrication of the electric screw drive (option) ....................................................... 10-17
11 Index .........................................................................................................................A-1
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Contents-8 00 0405 K-TEC40 - K-TEC155
Before you begin ...
1 Before you begin ...
1.1 Preliminary remarks
This operating manual is intended for the operating and maintenancepersonnel of the K-TEC injection moulding machine series with a clampingforce of 400 kN to 1550 kN. The manual contains instructions for the set-up,installation, operation and maintenance of the machine.
The sequence of the chapters corresponds as close as possible to thesequence of the work to be performed on the machine. Work, which is to bedone only by personnel with special qualifications, is specially marked.
Observe the operating instructions exactly, especially the safety instructions.The safety instructions are highlighted by bold print.
1.2 Warning symbols and instructions in the operating manual andon the machine
1.2.1 Warning instructions of danger to humans
This symbol warns of dangers due to electric power. Take precautionarymeasures that only qualified persons carry out the work which is markedaccordingly. When carrying out work, observe all necessary safety measuresand use only tools suitable for such work.
This symbol warns of dangers due to heat. Avoid touching hot machine partsand surfaces. If working on hot machine parts is necessary, always wearappropriate protective clothing, such as heat-resisting gloves and faceprotection.
This is a general warning symbol for non-specific dangers.
Warning of injury to hands
This symbol marks points at which no further mechanical safety devices canbe fitted to protect the hands.
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Before you begin ...
1.2.2 Symbols in the operating manual
ATTENTION / WARNING / DANGER
This symbol in bold print warns of dangers (danger to persons,machine and environment) throughout this manual. These instructionsmust be adhered to at all times.
NoteThis symbol does not denote danger but marks information for better understanding machine function.
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Before you begin ...
1.2.3 Warning instructions and symbols on the machine
This symbol warns of dangers due to hot material spatter. Wear suitableprotective clothing, especially heat-resisting gloves and approved safety eyeglasses when carrying out work so marked.
This symbol indicates that machine parts so marked may not be stood on orused as access.
This symbol indicates that important instructions must be checked in thisoperating manual before proceeding with work.
This symbol indicates that safe ladders or platforms must be available andused when mounting the machine.
This symbol indicates that safety guards and covers so marked must not beremoved.
This symbol marks the suspension points for transport with lifting or groundconveying devices.
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Before you begin ...
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Regulatory application
2 Regulatory application
The injection moulding machines, K-TEC series with clamping forces from400 kN to 1550 kN, are built for the production of moulded parts fromthermoplastic resins, thermosets, thermoplastic elastomers or rubber withfurther possible additives. For this, the particular material is plasticized withheat and friction and then injected through a nozzle into a hollow space in themould where it receives its shape.
For particular applications, additional equipment on the machine maybecome necessary. Observe the operating instructions and in particular theregulatory application of this additional equipment.
Every other application of this machine is prohibited.
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Safety
3 Safety
3.1 Basics
3.1.1 Responsibility
NoteThe instructions with regard to application and safety are provided according to the best knowledge of Ferromatic Maschinenbau GmbH; however, they do not release the user from testing their suitability for intended procedures and purposes. The user carries sole responsibility for the suitability and regulatory application of our products. Technical data are only recommended standard values. All liability on the part of Ferromatik Milacron Maschinenbau GmbH for consultation with regard to application and safety is excluded.
3.1.2 Conformity
This machine was built fail-safe in accordance with generally recognizedsafety regulations. It corresponds to EG council guidelines from 22 June1998 (98/37/EG) and the European standard for injection moulding machinesEN 201:1997.
3.1.3 Danger analysis and risk assessment
Danger analysis and risk assessment according to DIN EN 1050 orDIN EN 292 serves as basis for the safety concept and regulatoryapplication.
3.1.4 Layout of safety instructions
The danger symbols with corresponding explanation in this operating manualalert to remaining dangers, which cannot be avoided with regard toconstruction. The individual safety instructions are set out as follows:
Tab. 1: Layout of safety instructions
DANGER SYMBOLSWARNINGINSTRUCTIONS
SIGNAL WORD
Description
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Danger symbolsWarning instructions
Corresponding pictorial symbols indicate a danger or a necessary behaviour.
Signal word
The potential danger is emphasized by means of a corresponding signalword. The following signal words with corresponding meaning are employed:
Tab. 2: Use of signal words
Description
Descriptive warning texts are formulated plainly, briefly and concisely. Theyinform about the type of danger and possible potential of danger for personsand machine. They state possible behavioural and situation-related risks andconsequences when not observed, and refer to measures to be taken foravoiding dangers or if damage occurs.
SIGNAL WORD USAGE
DANGER! Total or partial non-observance of thisdirective can lead to serious damage tohealth. There is danger to life and limb!
WARNING! Total or partial non-observance of thisdirective can lead to serious damage tohealth or equipment.
ATTENTION! Disregarding these safety instructionscan cause damage to the equipment.
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Safety
3.2 Structural safety of the plant
The K-TECseries injection moulding machines were designed andconstructed under consideration of a danger analysis according toDIN EN 292 and prescribed harmonized technical specifications, which canbe found in the EU declaration of conformity. They therefore correspond tothe current state of technology and guarantee, as far as humanly possible,maximum safety.
To minimize structurally unavoidable dangers the machines are fitted by themanufacturer with various safety devices.
3.3 Safety devices
3.3.1 General
Before initial commissioning, at appropriate intervals, after modifications orrepairs, all safety devices must be tested for safe operation or at leastchecked for externally visible damages or faults.
Mechanical, electrical and hydraulic safety devices are fitted. They arecontrolled – up to machine cowling – by limit switches. When actuating thelimit switches, e.g. opening a safety gate, semi or automatic operation isimmediately interrupted and all further movement of the machine isprevented.
Check all safety devices for proper function in harmony with the instructionsin Chapter 6.3 "Checking safety devices". This applies especially to:
• emergency-off switch
• movable safety gates
• nozzle guard
• shutoff devices
• acknowledgement devices
ATTENTION!If the machine is fitted with peripheral equipment (e.g. Robot), for whichfunction the rear safety gate does not apply, the machine must only beoperated after the installation of the peripheral equipment has beencompleted and CE conformity restored. Non-observance of theseinstructions can lead to fatal injuries!
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3.3.2 Overview of safety devices
The arrangement of the most important safety devices is displayed here. Astandard machine is used as the basis.
NoteThe machine may be fitted by the user with additional safety devices depending on additional peripheral equipment. This operating manual does not make allowances for these.
Fig. 1: Safety devices on the machine.
1 Emergency-off key on IQT operator terminal2 Main switch at the electric cabinet3 Movable safety gates4 Nozzle guard5 Modular safety covers6 "Start" key on the IQT operator terminal (safety gate release)7 Oil level sight glass on oil tank8 Oil temperature monitor9 Overcurrent monitor for pump drive motor10 Emergency-off light
1
2
3
4
5
7 8
6
9
10
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Safety
3.3.3 Emergency-off switch
Reaction
The emergency-off function is triggered by actuating the emergency-offbutton. It effects:
• immediate cycle interruption
• blockage of all machine movement
• shutdown of motor
• shutdown of heating
• drainage of hydraulic accumulator system
• the emergency-off lamp flashes
• the message "Emergency-off key actuated" appears on the screen.
• manual operating keys must remain ineffective for duration of emergency-off function
Erasing
Erasing the emergency-off function is effected by disengaging emergency-offkey and actuating key "Start".
3.3.4 Main switch
Reaction
Switching machine ON/OFF – disconnection from supply when switched off,all functions disabled.
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3.3.5 Movable safety gates
Separating movable safety device Type III according to EN 201, issue 4/1997. The movable safety gate is doubly secured, electro-mechanically andhydraulically.
Note on "Gatestart" optionThe use of controlling safety devices is, according to EN 201: 1997 (article 5.2.1.1.4), permissible only up to a clearance of 630 mm between strain rods. The option "Gatestart" allows initiating a machine cycle in "semi-automatic" without actuating key "Start" by simply shutting the movable safety gate.
Reaction when opening safety gates
Interruption of electric and hydraulic power circuit; mould movement,injection, ejector and core functions are not possible. A message appears.
ATTENTION!Safety devices and safety margins are designed so that that the mouldsare smaller than or equal to the dimensions of the mould clampingplaten. For larger dimensions the safety margins must be checked orthe manufacturer must be consulted.
3.3.6 Modular safety covers
The machine covers are of modular design and can be designed according tocustomer requirement.
3.3.7 Nozzle guard
Movable separating safety devices Type I according to EN 201, issue 4/97.Secured by a limit switch.
Reaction during opening
Injection, plasticizing and injection unit movement are not possible. Amessage appears.
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3.3.8 Key "Start" (safety gate release)
To obtain safety gate release, i.e. to enable start of new cycle, the "Start" keymust be actuated each time the movable safety gates have been opened andclosed. The "Start" key can be used to erase fault messages and start a newmachine cycle in operating mode "Semi-automatic".
3.3.9 Safety gate release with power-operated safety gate (option)
To obtain safety gate release, i.e. to enable start of new cycle, the green key"close safety gate" must be actuated a second time after the power-operatedmovable safety gates have been opened and closed. The message "pleaseactuate Start key" erases.
The green key "close safety gate" can be used to erase fault messages andstart a new machine cycle in semi-automatic operating mode.
3.3.10 Oil level switch
Reaction
Switching off pump drive motor
3.3.11 Oil temperature monitor
Reaction
Switches off all machine movements at oil temperature of 60 °C, pumpcontinues to run to cool oil, at 65 °C pump motor switches off, accumulator isdrained.
3.3.12 Overcurrent monitor for pump drive motor
Reaction
Switching off pump drive motor
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3.4 Residual risk
Due to its power output an injection moulding machine produces highpressures, forces and temperatures. It represents a danger if it is notoperated by trained and instructed personnel and/or handled improperly ornot in accordance with regulations.
This can cause
• danger to life and limb of the operator or third party
• damage to the machine and other materials of the user.
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Safety
3.5 Responsibility of user
3.5.1 Accident prevention regulations and guidelines
The accident prevention regulations and guidelines of the respectivecountries apply for injection moulding machines. The user is responsible foradherence to these regulations.
Additional regulations to be adhered to are
• medical
• safety
• generally valid and
• legal regulations, e. g. industrial code
• training and regular control of personnel, in Germany according to VBG1, §7
3.5.2 Qualifications of personnel
The machine must only be operated
• by qualified, adequately trained and instructed personnel which is familiar with dangers (workplace ordinance).
Clearly set out the responsibilities of the personnel for work such asoperation, setting up, maintenance and repairs before such work iscommenced.
This applies especially to work on electrical, pneumatic and hydraulicequipment, which must be carried only by qualified, adequately trained andinstructed personnel familiar with the dangers.
3.5.3 Operating manual
Each person authorized with the installation, commissioning, operation,maintenance and repair of the machine, must first, before commencing suchwork, have read and understood the operating manual and adhere to theinstructions contained therein, especially the chapters related to "safety".
The operating instructions must be available at the machine at all times.
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3.5.4 Protective clothing
To avoid accidents it is strongly recommended to avoid wearing ties, scarves,rings or chains which could entangle with the machine.
Glasses During maintenance work in the injection unit area and especially in thenozzle and hydraulic nozzle shutoff area, unbreakable safety glasses mustbe worn. Contravention leads to serious eye injuries or loss of sight due to hotplastic materials.
Shoes For protection against squashing during setting up, steel-capped safety bootsmust be worn.
Gloves High temperatures may be encountered in the injection unit and mould area.During work on these units heat-resistant gloves must be worn.
Special personal clothing may be required depending on the material beingprocessed (see Chapter 3.6.2 "Unintentional material spray from nozzle").
3.5.5 Extraction
Some plastic materials when processed emit gases, vapours or dust. It is theresponsibility of the user to care for their extraction (see industrial code).
Such health-hazardous vapours can develop especially during excessiveprocessing temperatures. See data sheets of plastics manufacturers forrecommended processing temperatures (see Chapter 3.6.1 "Vapourshazardous to health").
If extraction equipment is to be installed directly on the injection mouldingmachine, the installation points provided on the mould clamping platen mustbe used. Otherwise consult manufacturer.
3.5.6 Safety devices and modifications
ATTENTION!Never bypass safety devices or alter their effectiveness.
Never perform alterations or modifications on the machine which couldadversely affect safety without the approval of the manufacturer. This alsoapplies to the installation and setting up of safety devices and valves as wellas welding work on load-bearing parts.
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Safety
3.5.7 Additional equipment
According to EN 201, the manufacturer of the machine is responsible for theinteraction of the machine with additional equipment only if he has designedtheir interfaces.
The user of the machine is generally responsible for the installation andremoval of optional equipment and adherence to safety requirements.Ferromatic Milacron is at all times available for consultation.
Lockable switch
DANGER!If the machine is fitted with a lockable switch with which the movement ofcores and ejectors can be released manually while safety devices are open,the operator must only use this switch when the design of the mould, cores,ejectors and their drives, excludes access to shearing and crushing positions.
Pneumatically actuated core pulls
DANGER!To prevent core movement while safety gate is open, do not operatepneumatically activated core pulls via the air valves of the machine (see alsoEN 201:1997 "Safe Moulds"). These air valves can also be activated whilethe safety gate is open and would therefore allow prohibited core movement.
Adequate protective function is only guaranteed when the standard corepulling control system is used for pneumatically activated core pulls, since itshuts down core movement while safety gate is open.
Safety barriers with access to danger areas of the machine
DANGER
• The installation of optional equipment must not reduce the injection moulding machine’s level of safety as specified in EN 201.
• If a standard movable safety device is removed from the machine or switched off and replaced by an additional safety device which allows access to a danger area of the machine, this additional safety device must be of a type that is specified for this danger area.
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Safety
Example: A movable safety gate (dividing safety device type III) is replaced by a fixedbarrier which allows access via a door to the mould area. The door of thebarrier must be designed as a dividing safety device of Type III. In addition,an emergency-off button within the barrier, an acknowledgement buttonoutside the barrier and a mechanical jam bar on the door of the barrier mustbe installed.
24-pole isolating socket for the safety limit switch
There is the option of connecting the safety limit switch of a safety device tothe machine via 24-pole isolating socket. When using optional equipment (e.g. cage with safety gate) the safety limitswitches of the machine must be disconnected and the corresponding safetylimit switches of the optional equipment connected to the isolating socket.
3.5.8 Screwed connections
Prescribed torque settings in accordance with specifications (seeChapter 10.2 "Torque values") are to be checked annually or after every5000 operating hours.
3.5.9 Hydraulic hoses
Safety rules, in Germany of safety regulations ZH 1/74 (issue April 1988) ofthe trade association, and corresponding DIN standards must be adhered to(see also Chapter 9.5 "Safety rules for hydraulic hoses").
OR
Safety limit switches on the machine
Safety limit switch on the optional equipment plus additional design-specific safety measure
Safety of the maschine or system
24-poleisolating socket
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Safety
3.6 List of safety hazards
3.6.1 Vapours hazardous to health
Some plastic materials when processed emit gases, vapours or dust. It is theresponsibility of the user to care for their extraction (see industrial code).
Such health-hazardous vapours can develop especially during excessiveprocessing temperatures. See data sheets of plastics manufacturers forrecommended processing temperatures.
If extraction equipment is to be installed directly on the injection mouldingmachine, the installation points provided on the mould clamping platen mustbe used. Otherwise consult manufacturer.
3.6.2 Unintentional material spray from nozzle
Inadequate drying, overheating or decomposition/disintegration of certainplastic materials could cause unintentional material spray out of the nozzle.The user must provide suitable personal protective equipment (see alsoChapter 3.5.4).
3.6.3 Hydraulics
Repair leakages on the hydraulic system immediately. These e. g. cause
• destruction of connections
• accidents (slipping on oil spill, injury through spurting oil)
• fires (spurts on hot machine parts)
• impaired machine operation
• wasted of time due to searching for leaks
ATTENTION!Ensure that when working on hydraulic systems or utilities
• Only qualified, adequately trained personnel familiar with the dangers, is authorized to perform the work!
• These are pressureless!
• The hydraulic system is secured against being switched on!
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Safety
Before starting work on hydraulic systems or utilities the main switchmust be disconnected. The pressureless state of the system must beconfirmed by means of a pressure gauge.
The mould on a horizontally closing injection moulding machine mustnot be closed. The mould on a vertically closing injection mouldingmachine must be supported.
3.6.4 Gas operated/filled systems
This includes e. g. airpress system (option), nitrogen accumulator of thehydraulic system.
ATTENTION!Ensure that when working on gas-powered and gas-filled systems:
• The system is pressureless!
• The system is secured against being started up!
• Only qualified, adequately trained personnel familiar with the dangers is authorized to perform the work!
• Observe the relevant regulations of the safety standards authority when these systems are fitted and operated (regular safety testing of pressure vessels by the authority!)
3.6.5 Electrical systems
• Ensure that work on electrical systems or utilities is only carried out by electrically qualified personnel and in accordance with electrical regulations (DIN 57113)!
• Main switch on OFF position
• Main switch is secured against being switched on by means of a lock!
• The system is disconnected!
Particular dangers associated with electrical energy:
• In accordance with VBG 4, § 5, paragraph 1 and 2, all stationary electrical systems must be tested every 4 years and non-stationary every 6 months.
• Regular tests/inspections of electrical equipment. Faults such as damaged insulation or loose cables must be repaired immediately. Find the cause!
• When fault occurs in energy supply, shut down the system in accordance with the shutdown instructions in the operating manual!
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Safety
• If work must be carried out on current carrying parts always enlist a second person in case of an emergency (actuating emergency-off key or main switch)!
• Secure work area with safety chain and warning sign!
• Use only insulated tools!
3.6.6 Control
Changes to control programmes are not possible by user! These must onlybe carried out by the technical customer service department ofFERROMATIK MILACRON!
3.6.7 Heated machine parts
Before starting work ensure that heated machine parts do not causeaccidents! Have available protective clothing (e. g. heat-resistant gloves)!
3.6.8 Other machine parts
Use only suitable tools and lifting equipment!
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Safety
3.7 In case of an emergency
3.7.1 In case of fire
If a fire breaks out at or around the machine proceed with safety shutdownprocedure immediately:
• Switch off main switch on electric cabinet.
• Switch off external voltage supply on main switch of the respective unit.
ATTENTION!In the event of a fire, time is of the essence!
Therefore, become beforehand familiar with:
• location and operation of fire extinguisher/blankets
A fire hazard is caused:
• by combustible liquids (hydraulic oil),
• by mixtures of liquids and gases (example: oil-oxygen mixture),
• overheated plastics
Applicable fire extinguishers according to fire class DIN EN 2:
• Powder extinguisher with ABC-extinguishing powder for solid, liquid and gaseous materials,
• Powder extinguisher with D-extinguishing powder for combustible metals,
• Carbon dioxide extinguishers for liquid, gaseous and solid materials.
WARNING!Under no circumstances must water be used for extinguishing a fire.Dangerous chemical compounds can develop in connection withplastic material.
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Safety
3.8 Safety instructions for machine operation
3.8.1 Normal operation
WARNING!• Safety instructions and danger symbols on the machine must be
kept in legible condition and observed!
• Any kind of hazardous work method must be avoided!
• Immediately repair any faults which threaten safety!
• Operate the machine only when all safety devices are installed and fully functional!
• Any variations which occur – including operational behaviour – must be reported immediately!
• Before switching on/starting up the machine/system ensure that no one can be endangered by the start-up of the machine/system!
• When working in an elevated position use safe ladders and platforms!
• If the machine is fitted with one or more vertical injection units, the operating company must provide safe ladders or steps for filling the hopper on the vertical injection unit, or employ a material conveyor recommended by Ferromatic Milacron. The pump motor must be switched off before filling the material hopper.
• Use only safe steps, ladders or platforms during maintenance work on the vertical injection unit(s).
• When working on the injection unit or on one of its components you must wear protective clothing (gloves, face protection etc.). Danger of sustaining burns from hot surfaces in the screw cylinder area and from escaping hot plastic material!
• When working on the machine (e.g. on the mould) switch off pump motor and ensure the system is pressureless!
• Spare parts must conform to requirements set by FERROMATIC MILACRON (original parts)!
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Safety
3.9 Setting, repair and maintenance work
ATTENTION!Screwed covers must only be removed after the drive has beenswitched off! The cover in the nozzle area must not be used as workingarea or for standing on!
The accident prevention regulation VBG1 states I § 41: "If setup,maintenance work or removal of faults can only be carried out when certainprotective and accident prevention regulations cannot be observed, then thiswork is only permitted if it is carried out by an authorized technician who iscapable of preventing any dangers which may arise."
• Inform operating personnel in time about the maintenance and repair work to be carried out!
• During all work, observe instructions in the operating manual for switching on/off as well as starting up/shutting down!
• Secure the system against being switched on during all repair and maintenance work.
• All maintenance and repair work must only be carried out while the machine is stopped, without power and pressureless!
• Secure main control unit with a lock and remove the key! Fix warning sign on main switch/operating panel!
• Basically, no safety devices must be removed or put out of operation (serious bruising and other life-threatening injuries could result). If removal of safety devices by authorized persons for setting up, repairs and maintenance is necessary, these safety devices must be immediately re-installed and their original state restored after maintenance and repair work has been completed.
• Check the function of safety devices after installation!
NoteSome of the machine components described are options. The equipment of the machine can vary in individual cases.
The injection moulding machine consists essentially of two mechanicalassemblies: the clamping unit (1) and the injection unit (2). The clamping unitserves to open and close the mould. The raw material is melted in theinjection unit and injected into the closed mould. Then the mould is openedand the cooled part is ejected. The cycle is then repeated.
The various machine functions are carried out through the interaction ofmechanical, hydraulic (3) and electric/electronic functions (4 and 5).
Machine function is determined by the IQT control programme. The requiredoperational parameters are entered via the IQT operator terminal. Theprogramme constantly monitors the operational state via a number of sensorsand switches and controls the corresponding sequence of all operations.
The clamping unit consists of a stationary (Fig. 3, Pos. 4) and a moving(Fig. 3, Pos. 6) mould clamping platen. The moving mould clamping platen issupported on the machine base. The two mould halves are mounted on theplatens. Mould movement takes place via two traverse cylinders, (Fig. 3,Pos. 2). Via the above-positioned re-suction tank, which is fitted directly tothe clamping cylinder (Fig. 3, Pos. 1) via a flange, the clamping cylinder isfilled with or emptied of hydraulic oil during mould movement. This shortensthe time for clamping pressure build up and release. After the injectionprocess the moulded part cools for a time in the mould. Then the mouldopens and a hydraulic ejector (Fig. 3, Pos. 5) ejects the moulded part fromthe mould. Ejection of moulded parts can occur parallel to mould movement.
The opening stroke of the mould is limited by the maximum opening stroke ofthe moving platen and the height of the mould. Depending on the form andsize of the mould, a shorter than the maximum opening stroke is advisable. Astroke measuring system constantly monitors the position of the mould.
The minimum mould installation height is determined by the minimumdistance between the two mould mounting platens. It can be altered byinstalling a longer or shorter pressure bolt and/or lengthening the tie barframe.
In the clamping unit fast movements with great force are carried out. To avoidinjuries to the operating personnel or material damage, electronic andmechanical safety devices form an integral part of the machine.
The front and the rear safety gate are equipped with switches, to prevent orstop movement of the clamping unit while the safety gate is open.
WARNING!Never disable the safety devices when operating the machine!
Manipulating safety devices (e.g. bridging or bypassing safetyswitches) is not in accordance with regulation and therefore prohibited.
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Description and function
4.2 Injection unit
4.2.1 Overview
Fig. 4: Injection unit (without safety covers)
1 Nozzle body and nozzle head2 Traverse cylinder (2 off)3 Screw cylinder (hidden)4 Screw (hidden)5 Material hopper with/without evacuating device (option)6 Feedthroat7 Injection cylinder (2 off)8 Extruder motor9 Supports with linear guides
8
9
2
1
7
5
463
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Description and function
4.2.2 Description
The injection unit consists of a screw cylinder (Fig. 4, Pos. 3) in which thematerial is melted and from which the melted material is injected into themould, and a material hopper (Fig. 4, Pos. 5; option) in which the rawmaterial (mostly granules) is filled for the injection moulding process. Thefeed throat (Fig. 4, Pos. 6) is water cooled to prevent the material frommelting and sticking in the material feed area.
The screw cylinder is equipped with heater bands for the plasticizing process.The screw serves to auger material from the hopper to the nozzle while at thesame time plasticizing and homogenising the material. As the plasticizedmaterial collects in front of the screw, the screw (Fig. 4, Pos. 4) is pushedback until the set plasticizing stroke is reached and the screw stops rotating.After the mould is closed and clamping pressure has been built up, theinjection process begins. The complete screw is pushed forward like a pistonby means of two parallel injection cylinders (Fig. 4, Pos. 7) and injects theplasticized material at high pressure through a nozzle (Fig. 4, Pos. 1) into themould.
Nozzle head and nozzle body form the connecting piece between screwcylinder and the mould.
The screw cylinder is held by a yoke. A hydro motor (Fig. 4, Pos. 8; electricscrew drive as option) which is fitted via flanges to the end of the screwcylinder, turns the screw inside the cylinder. The complete injection unitmoves on linear guides (Fig. 4, Pos. 9) by means of traverse cylinders (Fig. 4,Pos. 2).
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Description and function
4.3 Hydraulics
4.3.1 Overview
Fig. 5: Hydraulic system
1 Pressure accumulator2 Drive unit3 Oil filter4 Plate heat exchanger5 Main tank6 Re-suction tank
4
2
1
3
6
5
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Description and function
4.3.2 Description
K-TEC iseries injection moulding machines with a clamping force of 400 kNto 1550 kN are designed with different hydraulic drive concepts. Fromenergy-saving variable capacity pump drive for serial sequences ofmovement and multi-variable capacity pump drive for parallel movement upto accumulator hydraulics. The moulded part determines the choice ofmachine equipment. The hydraulic accumulator system installed in theK-TEC series injection moulding machines allows for high injectionperformance and the parallel operation of many machine functions e.g. themovement of ejectors and cores parallel to mould movement or in case of theKREC 155, with an additional hydraulic stage, mould movement parallel toplasticizing.
The accumulators (Fig. 5, Pos. 1) are charged by a smart load control of thepumps. Pressure relief valves protect the hydraulic system against excesspressure. Oil quantity and pressure are matched to each respectiverequirement. Control of hydraulic flow occurs via position-controlledproportional and flow control valves.
Air vents in the main tank (Fig. 5, Pos. 5) and re-suction tank (Fig. 5, Pos. 6)ensure that oil level fluctuations do not cause negative or excess pressure inthe tank. Air filters in the air vents prevent contaminants entering through theair.
The oil level in the main tank is indicated at the sight glass of the oil levelmonitor. If the oil level gets too low, the oil level monitor effects anemergency-switch-off. The oil temperature is monitored by a sensor. Theworking temperature of the oil lies at approximately 45°C. At 55°C a warningis displayed on the screen of the IQT operating terminal. At 60°C, workingmovement becomes impossible. If the oil temperature reaches 65°C thepump motor switches off.
Hydraulic components of the clamping unit
At the clamping unit, clamping pressure build-up, mould movement, core pullmovement (option) and ejector movement occurs via hydro cylinders. Via theabove-positioned re-suction tank, which is fitted directly to the clampingcylinder via a flange, the clamping cylinder is filled with or emptied ofhydraulic oil during mould movement. This shortens the time for clampingpressure build up and release.
Hydraulic components of the injection unit
At the injection unit, unit movement, injection, screw pull-back and theactuating of the hydraulic nozzle (option) occurs via hydro cylinders.Plasticizing occurs via the extruder motor. An electric screw drive is availableas an option
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Description and function
4.4 Electrics/electronics
4.4.1 Overview
Fig. 6: Electrics
1 Electric cabinet
4.4.2 Electric cabinet
Fig. 7: Electric cabinet
1 Operating hour meter2 Service socket3 Main switch4 Connections and sockets (option)
1
1
3
2
4
4
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Description and function
Power supply
NoteThe machine is connected in accordance with VDE regulations or the regulations of the local power supply station.
ATTENTION!The machine is equipped for connection to a TN-C-network (4 leads)with a PEN-terminal. When connection to a TN-S-network (5 leads) ismade, the bridging between the N-terminal bank and the PE-terminalmust be removed. The machine must be connected with clockwiserotation. Only peripheral equipment may be operated on the machinewhich conforms to VDE regulations for noise suppression on electricutilities and systems.
The wire cross section as well as main fuses must be installed in accordancewith the cover page of the electrical documentation (see service handbook,part I).
NoteFor additional consumption (mould heating, sockets etc.) the cross section of the wires must be dimensioned accordingly!
The connecting points for the power feed on the electric cabinet .1-Q1 andthe position of the PE-N bridge can be seen in the "Layout Plan PowerSupply Cabinet" and sheet 1 of group 1.
Motor, heating and control are separately protected by a circuit breaker. Themain switch .1-Q1 switches the machine of in total.
ATTENTION!The main switch is additionally equipped with an emergency-offfunction. It must be accessible at all times.
For this reason a service area of at least one metre must be kept freearound the machine.
The detailed mains connection plans are found in the service handbook.
NoteThe connections for the control transformers is laid out for 400 volt. Should the supply voltage from the net deviate, the connections on the control transformers must be altered accordingly.
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Description and function
4.5 IQT operator terminal
Overview
The IQT operator terminal consists of five parts:
– the screen relevant key board with a TFT flat screen,– the machine relevant keyboard,– an area with start key, operation mode selector switch, key switch and
the emergency-off key– the keyboard for special functions– operating panel with interfaces for printer (serial and parallel),
PC keyboard and EEPROM data carrier as well as disk drive
Fig. 8: IQT operator terminal
1 Screen relevant key board2 Machine relevant key board3 Key board switch4 Keyboard for special functions (option)5 Key board connections
NoteThe following paragraphs provide an overview of the functions of the individual keys.
1
2
3
4
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Description and function
Softkeys (Fig. 10; Pos. 2)
Fig. 11: Softkeys and key "HELP"
1 Softkeys with screen relevant occupation2 Key "HELP": displays Help texts on screen
The function of the softkeys (1) varies according to the selected screenwindow. The current function is displayed on the bottom of the screen via thecorresponding softkey.
Screen relevant and line relevant help texts may be called up via the "Help"key (2). Multi-page Help texts can be turned with cursor keys arrow up/arrowdown.
Screen relevant Help texts: • Put key switch in position 0
• Select required screen page
• Actuate "HELP" key
Line relevant Help texts: • Put key switch in position 1
• select desired line
• Actuate "HELP" key
1 2
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Description and function
Quick-select keys (Fig. 10; Pos. 3)
Fig. 12: Quick-select keys
1 calls up page 10 (data carrier and data transmission)2 calls up page 30 (cylinder heating parameters)3 calls up page 50 (clamping unit parameters)4 calls up page 60 (core pull and air units parameters)5 calls up page 40 (injection unit parameters)6 calls up page 70 (automation parameters, e.g. robot for extraction)7 calls up page 80 (graphic trend display of operational state)8 calls up page 20 (operating gate)9 calls up page 13 (freely composable screen pages)10 calls up page 17 (machine diagnostics)11 displays the list of alarm messages
NoteQuick-select and input keys can also be used for input of the respective letters and signs printed above left. For this the "ALT" key together with the desired key must be pressed. This input is only possible on certain screen pages.
2 3 4 5
6 7 8 9 10 11
1
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Description and function
Input keys (Fig. 10; Pos. 4)
Fig. 13: Input keys
1 Switch over print mode ASCII / Graphic2 Print out (only possible when printer is connected)3 ERASE key to erase messages4 Back up5 Keys for cursor control, i.e. to select individual input fields on screen pages6 CLEAR key erases the input in the field the cursor is currently in7 ENTER key to confirm entries8 Holding ALT key pressed changes the function of the remaining keys; they can
now be used for input of the respective letters printed above right9 Next page10 Switch over from foreground set of data to background set of data11 Direct page selection through input of page number12 Page in page function: Fade in a smaller second page through input of page
number13 Enlarge / reduce a second faded in screen page14 Previous page15 Selecting additional injection units, on multiple components/colours injection
moulding machines
NoteThe input keys can also be used for input of the respective letters and signs printed above left. For this the "ALT" key together with the desired key must be pressed. This input is only possible on certain screen pages.
12
3
4
5
6
7
89101112131415
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Description and function
Working with the screen (Fig. 10; Pos. 1)
When the machine is switched on the software starts automatically and theindex page appears on screen. The language can be selected via the firstthree softkeys.
Fig. 14: Table of contents (index) of the IQT-Control
1 Softkeys for language selection
After each start the fault message "Mains voltage failed" appears in the statusline. The message can be erased by pressing the "ERASE" key.
Direct page selection Certain pages can be selected via the quick-select keys or the input key "P",after which the page number is entered.
Page selection via index • Select screen page 0 "Table of contents"
• Select the desired group via cursor keys
• Actuate "ENTER" key
The index of the desired group is displayed
• Select the desired page via cursor keys
• Actuate "ENTER" key
The desired screen page is displayed
1
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Description and function
Page in page function • Actuate key "W"
• Enter number of the reduced page to be faded in
• Actuate "ENTER" key
Erasing page in page function
• Actuate key "W"
• Actuate "ENTER" key
NoteA cyclic update of actual values takes place in the reduced display.
Build up of screen pages
Fig. 15: Screen layout
1 Screen page number and title; information to unit and time2 Input field3 Adding shot counter4 Subtracting shot counter5 Input control window with information on selected print mode:
AS = ASCII or GR = graphic6 Occupation of softkeys7 Status information, from left to right: position of moving mould clamping platen,
cycle time, clamping pressure, ejector position, step display; fault messages alsoappear in this line
8 Status information, from left to right: position of screw, plasticizing time, screwspeed, selected injection unit with multi colour machines (additional function), oiltemperature; fault messages also appear in this line
9 Number of the screen line
1
2
34
56
7
8
9
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Description and function
Required value entry The respective values are entered directly via the number keys and must beconfirmed with the ENTER key. On some pages the last entered value can berepeated via softkey "Duplicate".
Before a required value is accepted a plausibility test takes place i.e. a test iscarried out to see if the value entered is valid. Incorrect entries can be erasedvia the key "CLEAR".
ActivatingScreen-saver
If no key is pressed for longer than 10 minutes, the screen is switched darkautomatically. Actuating any key reactivates the screen. The screen can beswitched dark manually on pages 0 to 9 by pressing softkey "Screen dark".
Fig. 16: Softkeys for language selection and screen darkening
1 Softkeys for language selection2 Softkey for screen darkening
1 2
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Description and function
Background colour The background colour of the screen can be switched from light to dark onscreen 17.0 in line 17.
Screen contrast and brightness
Contrast and brightness of the screen can be regulated via softkeys onscreen page 17.0.
Fig. 17: Screen background, contrast and brightness
1 Softkeys for regulating contrast2 Softkeys for regulating brightness3 Switching screen background to light/dark
NoteThe following graphic display provides an overview of the functions of the individual keys.
Machine relevant key block 1 (Fig. 18; Pos. 1)
Fig. 19: Machine relevant key block 1
1 Open mould2 Closing mould3 Injection unit forward4 Injection unit return5 Pump motor off6 Pump motor on7 Cylinder heating off8 Cylinder heating on9 Ejector return10 Ejector forward11 Injection12 Plasticizing13 Key A1: Back up14 Key A2: Back up15 Mould heating off16 Mould heating on
1
2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
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Description and function
Machine relevant key block 2 (Fig. 18; Pos. 2)
Fig. 20: Machine relevant key block 2
1 Move in core 12 Move out core 13 Move in core 24 Move out core 25 Key A3: Back up6 Key A4: Back up7 Reduce cylinder temperature8 Reduce mould temperature9 Move in core 310 Move out core 311 Move in core 412 Move out core 413 Activate air valve 114 Activate air valve 215 Activate air valve 316 Activate air valve 4
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
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Description and function
Operating panel for second injection unit (option)
The operating panel for the second injection unit installed in L position can beswitched on and off via the key switch. When operating panel is switched on,the message "Additional keys secondary unit active" appears on screen. Thekeys on the IQT operator panel (injection unit forward, injection unit return,plasticizing and injection) are then non-functional.
Fig. 21: Operating panel for second injection unit (option)
1 Emergency-off switch2 Key switch for switching operator panel on and off3 Unlock rear safety gate (option)
Possible functions
Fig. 22: Possible functions of second injection unit
1 Injection unit return2 Injection unit forward (when mould is closed and clamping force is built up)3 Plasticizing4 Injection
1 2 3
1 2 3 4
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Description and function
4.5.3 Key board switch
Overview
Fig. 23: Key board switch
1 Start key2 Operation mode selector switch3 Key switch for right of access4 Emergency-off switch
Operation mode selector switch (Fig. 23; Pos. 2)
The operation mode selector switch has four positions, each of which makepossible respective functions.
Operation mode "Setting" In operation mode "Setting" the following operations are possible with safetygates closed, i.e. the following keys are active on the machine relevantoperating panel (see Chapter 4.5.2):
– Open mould– Closing mould– Ejector forward and return– Injection unit return– Run down of air program/core pull programme in connection with
programme keys
NoteThe setting pressure entered in line 50.02 acts as maximum pressure
When changing from another operation mode to operation mode "Setting", allcurrently running processes are interrupted. If a hydraulic nozzle is fitted, itopens.
Operation mode "Manual" In operation mode "Manual" the following operations are possible with safetygates closed, i.e. the following keys are active on the machine relevantoperating panel (see Chapter 4.5.2):
– Open mould; upon pressing key, mould, with set values, openscompletely
– Close mould; upon pressing key, mould, with set values closescompletely
– Injection unit forward; for this, mould must be closed and clampingpressure built up
– Injection unit return– Injection; the injection pressure is limited to half of the maximum
injection pressure of the individual injection stages or to a maximum of85 bar.
– Plasticizing, as long as the key is pressed; for this, screw release musthave occurred
– Ejector forward and return; for this, mould opening stroke must havebeen reached and cores, if existing, must have moved out
When changing from operation mode "Semi-automatic" or "Automatic" intooperation mode "Manual" the currently running cycle is completed and themachine is then stopped.
4-24 00 0405 K-TEC40 - K-TEC155
Description and function
Operation mode "Semi-automatic"
In operation mode "Semi-automatic" a complete machine cycle with enteredparameters runs down. The cycle is started by pressing the "Start" (seeChapter 4.5.3) key. The cycle can only start, when the mould has movedopen fully and the ejector is in the rearward position and dwell time hasexpired. Also, no fault must exist which could prevent the cycle, e.g. amissing screw release.
Operation mode "Automatic"
In operation mode "Automatic" all machine cycles with set parameters, rundown sequentially until the process is interrupted by the operator or themachine control, e. g. the occurrence of certain faults.
When changing to operation mode "Manual" or "Semi-automatic" theautomatic cycle is completed. The started cycle runs to the end. Whenchanging to operation mode "Setting" the cycle is interrupted immediately.
4-2500 0405 K-TEC40 - K-TEC155
Description and function
Key switch (Fig. 23; Pos. 3)
The key switch can not be actuated without the correct key. There are fourcategories of keys:
– Key Y switches up to switch position 1– Key X switches up to switch position 2– Key Z switches up to switch position 8– Key P switches up to switch position 9
Fig. 25: Key switch
The key switch positions each allow access to a certain range of functions.
NOTE
Always set the key switch to position "0", when all settings have been carried out and never leave the key in the switch.
Range of functions atPosition 0 (key removable)
– Page selection– Help texts (screen relevant)– Activate tolerance excess counter (max. number of times tolerance
can be exceeded until machine standstill, screen line 80.06)– Standard graphics (or process graphics): Operating mode "Cyclic
measurement"– Required value entry on the user compiled screen pages 13.0 to 13.2;
password required
4-26 00 0405 K-TEC40 - K-TEC155
Description and function
Range of functions atPosition 1
– All functions of key position 0– Page and line selection– Required value entry– Mould height adjustment– Ejector zero point adjustment– Reading of data carrier– Standard graphics: Operating mode "Single display"– Help texts (line related)
Range of functions atPosition 2
– All functions of key position 0-1– Writing on data carrier– Build up of user compiled screen pages 13.0 to 13.2
Range of functions atPosition 3
– All functions of key position 0-2– Text input in user compiled screen pages 12.3 to 12.6– Screw cylinder definitions on screen page 19.1– Establishing a password to enable required value input on the user
compiled screen pages 13.0 to 13.2 in key switch position "0"– Screen pages 22.0 and 23.0 become visible
Range of functions atposition 4–7
Function as position 3
Range of functions atPosition 8
– All functions of key position 0-7– Selecting diagnostics pages starting from screen page 87.0– Regulator adjustment for cylinder heating
Range of functions atPosition 9
– Diagnostics mode, only for service purposes
4-2700 0405 K-TEC40 - K-TEC155
Description and function
Card reader for IQT.net (option)
Right of access to the IQT.net can be gained either via the 10-stage keyswitch or via a smart card reader.
Via the smart card reader, right access is regulated with access cards (smartcards). These access cards contain the user code (digits or text) and the userlevel (0 to 9). The user levels 0 to 9 release the same functions as the keyswitch positions 0 to 9.
In addition for later required value inputs, the contents of the freelycomposable screen page 13.1 to 13.2 can be stored on the access card.
Creating access cards Access cards can be created directly at the IQT control. To do this, an accesscard with user level 8 is required (=mastercard).
• Insert the access card with user level 8
• Compile freely composable screen pages 13.0 to 13.2
• Select screen page 13.9 to produce new access card
• Remove the access card with the user level 8
• Insert new access card
• Set user level in line 2, i.e. enter a value between 0 to 9
• Enter user code in line 3 (digits or text)
Fig. 26: Screen page 13.9: "Card reader"
4-28 00 0405 K-TEC40 - K-TEC155
Description and function
• Determine in line 6 to 8, which of the three freely configurable screen pages are to be stored on the access card (value 1)
• Actuate softkey "Create card"
The question "Create new access card yes=1/no=0?" appears
• Enter value 1 and actuate key "ENTER"
A new access card with the set user level is created and the contents of thefreely configurable screen pages are stored on the card.
Modifying access cards • Insert the access card with user level 8
• Select screen page 13.9
• Remove the access card with the user level 8
• Insert the access card to be modified
• Actuate Softkey "Read card"
The user level, the user code and the freely configurable screen pages 13.1to 13.2 stored on the access card are indicated. The contents of the freelyconfigurable screen pages is displayed after having selected thecorresponding freely configurable screen page 13.1 to 13.2.
• Make modifications
• Actuate softkey "Create card"
• The question "Create new access card yes=1/no=0?" appears
• Enter value 1 and actuate key "ENTER"
NoteThe user level (0 to 9) stored on the access card corresponds functionally to the respective key switch position of the 10-stage key switch.
The user code stored on the smart card is used for operating data collection. When required value changes are recorded, the user code is also recorded.
Drawn access card corresponds to key switch position 0; which, e. g. is required to display page related Help texts.
new access cards can be ordered under part number 0132524 from Ferromatic Milacron.
4-2900 0405 K-TEC40 - K-TEC155
Description and function
Emergency-off switch (Fig. 23; Pos. 4)
Fig. 27: Emergency-off switch
The emergency-off switch immediately stops all machine movement. At thesame time the message "Emergency-off key actuated" appears on theDisplay.
ATTENTION!Activate the Emergency-off immediately, when persons are endangeredby the machine or material damage threatens.
Watch for other people near the machine and care for their safety!
Further information: Chapter 3 "Safety"
4.5.4 Keyboard for special functions, option
Fig. 28: Keyboard for special functions
Keys "S1" to "S16" can be occupied with special machine functions, e. g.additional air valves, moving additional cores in and out as well as specialfunctions related to special programmes.
4-30 00 0405 K-TEC40 - K-TEC155
Description and function
4.5.5 Key board connections
Overview
The lower section of the IQT operator terminal contains connections forprinter (serial or parallel), PC keyboard and EEPROM data carrier as well as3.5" -disk drive.
Fig. 29: IQT operator panel connections and disk drive
1 EEPROM data carrier or smart card reader for IQT.net (option)2 3.5" disk drive3 Printer connection4 PC keyboard connection5 "Schuko" protective socket6 Back up
1
2
3
45
6
4-3100 0405 K-TEC40 - K-TEC155
Description and function
4-32 00 0405 K-TEC40 - K-TEC155
Installation
5 Installation
This chapter describes the requirements for machine location and theprocedures for installing and levelling the machine.
5.1 Technical data for machine location
The dimensions of the machine are found in Chapter 10 "Technical data".Allow at least one meter of space around the machine for service andmaintenance work. Additional space is required to completely open the doorsof the electrical cabinet. Further information is found in the machineinstallation plan. Additional space could be required for removal of the screwor a strain rod.
5.1.1 Noise emission value
In compliance with the third ordinance of the German equipment safety law(Machine Noise Information Ordinance - 3. GSGV) of January 18, 1991, thework place related emission values LPA in db (A) stated in the table belowwere measured on Ferromatik Milacron injection moulding machines.
The measurements were carried out according to DIN 45635, ISO 3744,ISO 6081 and EN 201. The results achieved are a mean value, consideringambient conditions. They are valid exclusively for standard machines relativeto the position of the operating personnel.
Fig. 30: *) with pulsation damper (optional equipment)
5.1.2 Permissible ambient conditions
• Temperature and humidity according to EN 60204-1:1997
• Lighting according DIN 5035, part 2
db (A) Standard
db (A) S-Version
K-TEC 40 72 78 / 65*
K-TEC 60 74 79 / 67*
K-TEC 85 75 80 / 72*
K-TEC 110 76 80 / 75*
K-TEC 155 78 78
5-100 0405 K-TEC40 - K-TEC155
Installation
5.2 Installing the machine
5.2.1 Preparation for delivery of machine
The dimensions of the machine are found in the installation plan inChapter 10 "Technical data". Please observe that at least 60 cm of free roomis required on the hydraulics side for adequate access to the hydraulics.
It is recommended to install the machine elastic. The anti-vibration padsdampen machine vibration and prevent transference of vibration to theenvironment surrounding the machine. They allow for easy alignment of themachine.
Equalizing disc If the 20 mm lifting height of the anti-vibration pads is not sufficient forlevelling adjustment, an equalizing disc can be inserted between the machinebase and anti-vibration pad.
Fig. 31: Equalizing disc part no. 0004841
Do not remove transport brackets from the machine before it is in itsdesignated location.
Please observe the following requirements when selection the machinelocation:
• The foundation must comply with the permissible load per square centimetre rating necessary to support the machine.
• Adequate space must be provided for peripheral equipment (handling devices, automatic loaders, coolers, conveyors, and packaging, cutting and other processing devices).
• Make provisions for connecting the machine (power, cooling water supply and drainage, air pressure)
• An overhead crane and/or lift truck must be available for machine maintenance and mould handling.
5-2 00 0405 K-TEC40 - K-TEC155
Installation
5.2.2 Preparation for transport within company's premises
ATTENTION!Whenever the machine is transported all shipping brackets must beinstalled to the clamping unit and injection unit.
Transport the machine with mould clamping platens fully opened.
• Move mould clamping platens to maximum distance between platens.
• Switch machine off at main switch.
• Disconnect power and water supply from machine.
5.2.3 Transporting the machine
ATTENTION!Use only lifting devices (e.g. crane) with a load rating that is adequatefor the total weight of the machine (observe safety tolerance).
Before lifting the machine observe the installation plan with regard toweight and suspension as well as diameter of the transport slings. Thetotal weight of each machine in Technical data (Chapter 10) serves as aguide. The weight may vary depending on optional equipment.
Use only undamaged impact chains or slings. Never shorten impactchains or slings with knots or bolts.
Make absolutely sure that the load capacity of the impact chains orslings is selected higher than the corresponding sling-to-load angle.Use the following table as a guide.
To remain within the load rating of the slings, the sling-to-load angleshould remain as close as possible to 90°, even when additional slingsbecome necessary.
5-300 0405 K-TEC40 - K-TEC155
Installation
Fig. 32: Sling-to-load angle for chains and slings
Load capacity of chains and slings
Sling-to-load angle α
Actual load capacity in % of rated load capacity
90 ° 100.0 %
75 ° 96.6 %
60 ° 86.6 %
45 ° 70.7 %
30 ° 50.0 %
15 ° 25.8 %
5 ° 8.7 %
5-4 00 0405 K-TEC40 - K-TEC155
Installation
• Remove packaging materials, but leave shipping brackets installed.
• Safely secure the impact chains or slings to the four transport eyes.
• Lift machine slowly and adjust chains if necessary; set down machine again to do this.
Fig. 33: Four transport eyes
DANGER!Make sure that no person or parts of the body, e. g. feet, are underneaththe suspended machine.
• Lift machine and move it to the designated location.
• The machine on delivery must be set on a prepared support to install the anti-vibration pads (see Fig. 34, page 6) (if not previously installed); make sure the support does not block the installation points of the pads.
DANGER!Do not install the anti-vibration pads to a hanging, unsupportedmachine!
• Install the anti-vibration pads supplied.
• Lift machine and remove support.
• Slowly set down machine on floor.
• Remove lifting devices.
• Remove shipping brackets.
• Check machine for transport damage and check shipping documents against shipment.
• If necessary fill out the enclosed transport damages forms and immediately report the damage to Ferromatik Milacron Maschinenbau GmbH.
5-500 0405 K-TEC40 - K-TEC155
Installation
WARNING!When installing the machine ensure that hoses do not protrude into anarea where they could be damaged. Failure to follow these instructionscan lead to injury and/or machine damage.
The transport supervisor/mechanic from Ferromatik Milacron, Mr. ……………..has taken note ofthese damages.
We request repairs/spare parts delivery/rectification of damages. We expressly confirm that thedamages on the machine were not caused by us but that the machine arrived at our premises in thiscondition.
Location: ……………………………, Date…………………………..
___________________________ ___________________________ (Signature) (Signature of witnesses)
Address:
p.s. Please send the original consignment note with this report.
Comments by Firma Ferromatik Milacron Maschinenbau GmbH:Taken note of damage on: .......... from: ................................................Damages referred to Albingia Versicherung AG, Hamburg on ……
5-700 0405 K-TEC40 - K-TEC155
Installation
5.2.5 Erecting the electric cabinet
Only for K-TEC 155 For transport, the electric cabinet is fixed to the machine with two brackets. Inorder to avoid transmission of vibration from the machine to the electriccabinet, the electric cabinet should be removed from the machine before themachine is commissioned and installed on the levelling pads which havebeen supplied.
NoteThe packaged levelling screws and levelling pads are contained in the electric cabinet.
Procedure: • Screw levelling screws (4x) into the threaded holes of the brackets.
• Set levelling pads underneath and screw in levelling screws until the electric cabinet is supported on the levelling pads.
• Secure levelling screws with counter nuts.
• Remove screws with which the brackets were secured to the machine base.
• Align electric cabinet horizontally.
Fig. 35: Alignment elements for electric cabinet
1 Machine base2 Retaining screws3 Levelling screws and elements4 Electric cabinet
21 3
4
5-8 00 0405 K-TEC40 - K-TEC155
Installation
5.2.6 Installation with crane*
WARNING! Cranes, lifting devices, slings, eye bolts and other lifting equipmenthave a maximum load rating which must not be exceeded. Observe allvalid standards and regulations. Failure to follow these instructions canlead to serious injury and/or machine damage.
Procedure: • Lift the crane with suitable lifting device such as fork lift or hall crane. Use the area intended for this (see drawing).
• Adjust the crane so that the fixing bores are set about 2 mm before the threads provided on the nozzle plate.
• Turn the four retaining screws by hand and insert the dowel pin provided into its seating by lightly tapping it with a plastic hammer. Now the crane is fixed.
• Check the vertical alignment of the strain rod as well as the horizontal alignment of the crossbeam.
• Now "cross-tighten" the four retaining screws to the torque value specified in the table.
• Insert the lifting crab preassembled at the factory into the guides by loosening the lifting bolt.
• Tighten the lock nut against the retaining nut so that it acts as counter nut.
The load rating specified on the crane must not be exceeded under anycircumstances!
*) Optional equipment
Maintenance The retaining screws and lock nut must be checked for tightness at suitableintervals as must the vertical alignment of the strain rod and the horizontalalignment of the crossbeam.
Sling
Machine type Torque value (Nm) Dowel pin
K-TEC 40 210 No
K-TEC 60 210 No
K-TEC 85 210 No
K-TEC 110 210 No
K-TEC 155 210 Yes
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Installation
5.3 Aligning the machine
NoteFor proper machine operation it is absolutely necessary to level the machine precisely along and across its axes. If the specified alignment is not attainable Ferromatik Milacron customer service must be informed.
The individual steps may need to be repeated until both axes are level.
Machine alignment must be checked at least once a year or after5000 operating hours.
Proper alignment of the machine must be checked:
• before disassembling the clamping unit,
• before exchanging a tie rod, a tie rod nut,
• before disassembling the tie bar frame
5.3.1 Aligning the base
Measuring instruments Frame level 0.1 mm, internal micrometer with extension, measuring gaugewith magnetic stand, spirit level 0.1 mm, ground shaft with 0.1 mm maximumconcentricity and taper or equivalent straight edge
– Testing spirit level before use: Inflection test– Permissible tolerance for all test points: 0.2 mm/m– Machine stands on all anti-vibration pads, all levelling screws are
brought to torque evenly– Machine is filled with oil, preserving agents are removed
5-10 00 0405 K-TEC40 - K-TEC155
Installation
Alignment levels and anti-vibration pads
Fig. 36: Alignment levels
The machine is aligned by means of height-adjustable anti-vibration pads:The rough alignment is made via the outer elements (alignment levels 1and 2); the fine alignment via alignment levels 3 and 4, which supports themachine base.
If a dual arrangement of pads is used there should be an even loaddistribution.
Move machine to alignment position
• Switch machine on (the individual operations are described in Chapter 7 "Running and operating the machine").
• Bring moving mould clamping platen into central position.
• Move injection unit forward until nozzle head is flush with the clamping surface of the mould clamping platen.
• Heat screw cylinder to 220 °C.
• Move screw into forward position.
1
24
3
5-1100 0405 K-TEC40 - K-TEC155
Installation
Align mould clamping platen
• Put spirit level on the lower tie bars. The contact point should be approximately 10 mm from the platen.
• Put spirit level over the lower tie bars with the aid of a shaft or straight edge.
• Turn levelling screws on the anti-vibration pads (alignment level 1), until both spirit levels are aligned.
The alignment of the stationary and moving mould clamping platens as wellas the end plate must be checked as described above and adjusted ifnecessary. Several repeats may be necessary depending on adjustmentstroke. The alignment sequence described must be followed.
5-14 00 0405 K-TEC40 - K-TEC155
Installation
Supporting the base
If all levels are correct the machine base in alignment level 3 and 4 can besupported.
• Turn levelling screws on the anti-vibration pads of levels 3 and 4. The elements should carry load but have no influence on measurement.
Checking mould clamping platen
• Put frame level on the stationary and the moving mould clamping platen.
Clamping platens must be angular to the tie rod frame.
Fig. 40: Measuring layout of mould clamping platen
After service work:
Checking parallelism of guide rails to tie rods:
• Put spirit level 100 mm from beginning / end of guide rails
NoteDuring operation an even lubricating film must form around the tie bars.
5-1500 0405 K-TEC40 - K-TEC155
Installation
5.3.2 Aligning injection unit
Fig. 41: Aligning injection unit
1 Contact points for spirit level
• Position spirit level on the linear guides in front of cross member and behind the rear cross member for aligning laterally.
• For longitudinal alignment position spirit level on the piston rods of the injection cylinder.
• Turn levelling screws in the cross members until both spirit levels are aligned.
Fig. 42: Measuring layout injection unit
1
11
5-16 00 0405 K-TEC40 - K-TEC155
Installation
5.3.3 Checking the alignment of the nozzle head in the stationary mould clamping platen
WARNING!To avoid strain during operation the nozzle head must be seated totallycentric to the stationary platen. Disregarding these instructions leads toincreased wear on the nozzle head and serious machine damage.
Prerequisite for correct measurement is a heated screw cylinder.
• Move injection unit forward until nozzle head is flush with the clamping surface of the stationary mould clamping platen.
Fig. 43: Checking nozzle alignment
• Measure nozzle distance to clamping platen horizontally and vertically with callipers. Maximum permissible tolerance is 0.1 mm
5.3.4 Aligning nozzle on sprue bushing in the mould
NoteThe injection unit is aligned before delivery. If misalignment is detected after checking the nozzle head, inform Ferromatic Milacron customer service. If misalignment is undertaken as follows it is done under own responsibility!
Measuring layout
• Position spirit level as decribed in (see Chapter 5.3.2 "Aligning injection unit")
5-1700 0405 K-TEC40 - K-TEC155
Installation
Procedure
NotesWhen aligning nozzle in the clamping platen also observe the horizontal position of the injection cylinder axis!
When aligning nozzle also observe the parallel position of the injection cylinder axis to the machine axis!
• Heat screw cylinder to 220 °C or processing temperature.
• Purge screw cylinder and move screw into forward position.
• Loosen the cam on the roller bearing of the screw cylinder support so that the roller bearing is free.
• Move injection unit into stationary mould clamping platen until the nozzle head is in the centre hole.
• Loosen traverse cylinders from the stationary mould clamping platen.
Correcting vertical deviation
• Vertical deviation up to 0.2 mm must be corrected by adjusting the cam on the roller bearing of the screw cylinder support.
Fig. 44: Correcting vertical deviation
1 Adjusting screws in the cross members2 Linear guides3 Traverse cylinder4 Injection cylinder5 Counter nut
12
4
3
5
5-18 00 0405 K-TEC40 - K-TEC155
Installation
• At larger deviations loosen the cross member retaining screws located under the cross member.
• Turn setting screws on cross members until nozzle head is vertically aligned. To do this, adjust cross member setting screws evenly.
• Check with spirit level; re-adjust if necessary until injection cylinder axis is level.
Correcting horizontal deviation
The injection unit can be moved horizontally by loosening the retainingscrews on the cross members.
• Correct horizontal deviation by moving injection unit.
• Retighten retaining screws on cross members.
• Install traverse cylinder to stationary mould clamping platen and level towards rear.
• Move injection unit to rear limit stop: Screw cylinder must not move out of its centric position.
• If necessary adjust the mechanical stop on the traverse cylinder piston rods.
• Checking and setting synchronism of injection cylinder piston rods:
– Move screw into forward position– To do this, bring operation mode selector switch in position "manual"
and actuate key "injection"Injection cylinder moves to mechanical stop. This must take placesimultaneously, free of impact and distortion.
• Correcting measures
– Loosen counter nut on piston rod– By turning the piston rod, determine the position in which the
approach to the mechanical stop occurs simultaneously, free ofimpact and distortion
– Tighten counter nut on piston rod
5-1900 0405 K-TEC40 - K-TEC155
Installation
5.3.5 Checking mould clamping platen parallelism
Mould clamping platen parallelism is measured 20 mm before minimum andmaximum mould opening width. This prevents the clamping cylinder rod fromsitting on the limit stop and distorting the measurement through strain.
Fig. 45: Measuring clamping platen parallelism, example
• Move to each respective measuring point.
• Measure 4 points with internal micrometer. The measuring points are to be selected 50 mm from the inside of the rods to the centre of the platen.
• Record measurements and compare.
The permissible tolerance for all matching measurements depends on themachine:
– K-TEC 40 - K-TEC 60 = 0.25 mm – K-TEC 85 - K-TEC 155 = 0.30 mm
When measurements lie outside the tolerance, all alignment levels must bechecked and adjusted.
NoteWhen parallelism is incorrect but no deviation is detected, Ferromatik Milacron customer service must be notified. Do not operate the machine under any circumstances.
5-20 00 0405 K-TEC40 - K-TEC155
Installation
5.4 Cleaning, filling and connecting the machine
5.4.1 Cleaning the machine after delivery
Removing rust protection
ATTENTION!• All rust protection must be removed completely, since it could
damage the hydraulic cylinder seals during machine operation. Do not use chlorinated hydrocarbons, such as PER, TRI or similar products to remove the rust protection!
• Solvents may be used to remove the rust protection from the rod mountings, the bore holes of the end plate and the mould clamping platen.
• When using solvents, provide for adequate ventilation in the work area!
• Solvents are flammable! Make sure there is no open fire or danger of sparks in the work area! Dispose of solvent soaked rags immediately and properly!
Procedure • Remove rust protection from all blank parts (e.g. hydraulic cylinder, guides) with solvent.
• Immediately lubricate all bare parts with acid-free oil.
5.4.2 Fitting the material hopper
DANGER!Do not step on machine parts which are marked with correspondingwarning symbols.
Always use tested and approved ladders or scaffolds and make surethey are set up correctly.
• Install hopper to feed throat
5-2100 0405 K-TEC40 - K-TEC155
Installation
5.4.3 Filling with hydraulic oil
CAUTION
Avoid constant skin contact with the hydraulic oil. Thoroughly cleanskin after every contact with the oil. If eyes come in contact with oil,thoroughly rinse them with copious quantities of water.
Main tank and re-suction tank must be filled separately with hydraulic oilHLP 46 at maximum mould opening width. Precise specifications are listed inchapter "Lubricant recommendations".
Bleeding pump housing
Before filling the hydraulic tank with oil the pump housing must be bled.
• Remove upper oil leakage connection of the pump
• Fill housing with hydraulic oil until oil emerges
• Reinstall leakage oil connection
Fig. 46: Hydraulic pump
1 Oil leakage connection
Oil tank capacity [l]
K-TEC 40 175
K-TEC 60 190
K-TEC 85/ K-TEC 110 290
K-TEC 155 450
1
5-22 00 0405 K-TEC40 - K-TEC155
Installation
ATTENTION!All hydraulic oil must be pre-filtered to 5 microns before it is added tothe system. Failure to follow these instructions can lead to machinedamage.
Procedure • Remove cover from main tank
• Open filler neck on main tank
• Open filler neck on re-suction tank
Fig. 47: Oil filler openings
1 Oil filler opening on the re-suction tank2 Oil filler opening on the main tank
• Fill re-suction tank until oil returns to the main tank via the transparent return hose (see Fig. 48)
Fig. 48: Re-suction tank
1 Re-suction tank, underside2 Return hose
2
1
2
1
5-2300 0405 K-TEC40 - K-TEC155
Installation
• Fill main tank until oil level lies in the upper half of the oil level sight glass
• Run a few machine cycles with minimum mould installation height and an opening stroke of 200 mm
• Check oil level in main tank
• Top up main tank until oil level lies in the centre of the sight glass
Fig. 49: Oil level sight glass and monitor
1 Oil level sight glass on main tank
ATTENTION! During the initial filling process and after each oil change the hydraulicsmust be bled (Checking hydraulic functions (Chapter 6.4)). Pleaseobserve that for problem-free functioning of your injection mouldingmachine the oil checks/changes prescribed in Chapter 9 "Repairs andmaintenance" must be adhered to.
1
5-24 00 0405 K-TEC40 - K-TEC155
Installation
5.4.4 Cooling water connection
A 3/4" cooling water feed connection and a 3/4" cooling water drainconnection with corresponding flow must be fitted.
ATTENTION!Ensure that the cooling water quality is suitable! See Chapter 10.1"Instructions on the operation of the plate heat exchanger".
Lay or fit the supply and drain hoses so that they cannot be damaged orcause tripping.
• Connect the cooling water supply and drainage
The main cooling water supply and drain lines are to be fitted with G1" up tothe machine. The connection of the cooling water manifold is distributed withG ¾".
Openings in the machine base are provided for laying piping. Together withthe c-profiles for mounting, auxiliary units can be installed and connected atmany points.
When installing pipes, intermediate hose pieces for supply and drainage mustbe used. The cooling water manifold is fitted with ¾" hose fittings. The supplyline must be connected to the lower hose connection, the drain line to theupper connection.
The supply and drain lines to and from the mould are connected at the bottomof the manifold. Supply at the front and drain at the back, according toillustration (observe arrows).
Wittmann flow regulator series 101
Fig. 50: Flow regulator
Common drain
Common supply
Mould
5-2500 0405 K-TEC40 - K-TEC155
Installation
The arrangement of one regulating valve each for the forward and the returnflow in each cooling water circuit allows the control of the cooling water floweither in front of or behind the mould, resulting in pressureless or pressurizedwater circulation.
If the cooling water circulation is severely throttled, it is of advantage toregulate in the return flow, to guarantee a full flow through all cooling waterchannels.
The cooling water manifold can also be connected to a heating unit forcontrolling mould temperature. The maximum permissible water temperatureis 100°C at a maximum of 4 bar (see thermometer).
Observe that the water connection for the feedthroat is supplied separatelywith cooling water from the manifold.
The transparent tubes with graduation lines and floats allow the water flow ineach cooling water circuit to be checked at any time. The tubes are easy toclean. After screwing off the sealing cap the tube can be cleaned with a brushor lifted out if necessary. The floats in the tubes rise with increasing flow. Theposition of the floats indicates the volume of flow. This is indicated in thediagram.
Flow diagram: Wittmann flow regulators series 101 and 301*
Fig. 51: Flow diagram
*) Connection of cooling water manifold with G 1 ¼"
Flow area per circuit: 0 to 10 l/min (30 l/min*)
Max. pressure: 10 8 6 4 bar
Max. temperature: 40 60 80 100 °C
Series 101*200
Series 301*
1
l/min
Scal
ing
10
100
10 20 30
5-26 00 0405 K-TEC40 - K-TEC155
Installation
Blow-off valve
A blow-off valve is installed in the lower distribution channel of the coolingwater manifold.
The water can be blown out of the cooling channels with this valve before amould change. This prevents the cooling channels and the surfaces of mouldfrom rusting (due to leaking water) while in storage.
A compressed air hose is connected to the G ¼" thread. By opening the shut-off valve the water in the mould and the hoses can be blown out prior tomould change. This makes a clean mould change possible.
Procedure: • Shut off water supply
• Open air pressure shut-off valve
• By opening the control valves of the individual circuits (supply and return) and shutting off the other circuits, each circuit is blown out until the water is pressed out of the sight glass.
Fig. 52: Water connections on the plate heat exchanger
1 Plate heat exchanger2 Water discharge3 Water supply
G 1/4"
1
3
2
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Installation
Make sure that the oil flow and the water flow run in opposite directions!
Fig. 53: Water connections on the feedthroat
1 Feedthroat2 Water connections
1
2
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Installation
5.4.5 Electrical connection
The electrical documentation is contained in the Service Handbook and in thefolder in the document basket in the door of the electric cabinet. The electricaldocumentation contains the connection data as well as all the informationabout the electrical wiring of the machine.
DANGER!Connecting the machine to the mains power supply must only becarried out by qualified electrical personnel!
Switch off the main switch and secure it against being switched on (e.g.with a warning sign at the main switch).
The machine is equipped at the factory for connection to a TN-C-network (4 leads) with a PEN-terminal.
• Open switch cabinet
DANGER!When connection to a TN-S-network (5 leads) is made, the bridgingbetween the N-terminal bank and the PE-terminal must be removed.
• Connect the mains cable to the main switch and the PE-terminal (with TN-S-network to N- and PE-terminal)
• If the mains voltage deviates from 400 V, match the control transformers .1-G1 and .1-T6, on the primary side, to the actual mains voltage; a reduction of 5% corresponds to 380 V and an increase of 5% to 420 V
• All terminal screws in the electrical cabinet should be checked and tightened, if necessary
• Check modules in control plug-in unit and connection plugs for proper seating and contact
• Check the batteries in the control (CPU module, socket 1) and the IQT terminal if they are switched on.
• Close switch cabinet
• Check all plug connections and control leads for the hydraulic valves and safety switches for correct seating
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Installation
Fig. 54: Electric cabinet
1 External main switch2 Internal main switch
5.5 Disassembly of injection moulding machine
Only skilled personnel must disassemble the injection moulding machine.Observe the disposal regulations applicable for each country, especially inregards to hydraulic components, hydraulic oil and electronic components
Disposal Hydraulic oil is to be disposed of according to the European disposalcode 130106. It is recommended to have hydraulic oil reprocessed orincinerated at an approved reprocessing plant or pass it onto an approveddisposal company.
1 2
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6 Start up procedure
The machine must only be started up after the machine has been installed,connected and filled with hydraulic oil, in accordance with the proceduredescribed in Chapter 5.
6.1 Switching on machine
DANGER!Only electrically qualified personnel must check the electricalequipment.
The supply side of the main switch in the electrical cabinet remains liveeven when the main switch of the machine is switched off.
• Switch on main disconnect switch
• Turn on machine with main switch in electrical cabinet
• Wait until screen page 0 is displayed
6.2 Rotational direction of the electric motor
6.2.1 Checking function and rotation of motor
ATTENTION!Running the motor in the wrong rotational direction can lead to pumpdamage.
Fig. 55: Electric motor of hydraulic pump
1 Cooling fan
1
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Start up procedure
• Remove side cover
• Switch on main switch
Fig. 56: Machine relevant key board
1 Pump motor off2 Pump motor on
• Actuate key "Pump motor on" and immediately actuate key "Pump motor off"
• The motor receives a short starting kick.While it is running watch direction of rotation (direction of arrow)
• Correct direction of rotation: When viewing the fan, the motor must run in a clockwise direction
• If direction of rotation is incorrect continue with Chapter 6.2.2 "Setting rotational direction of motor"
• If direction of rotation is correct continue with Chapter 6.2.3 "Checking electric motor and hydraulic lines"
• If motor does not rotate or the overload protection responds, continue with Chapter 6.2.3 "Checking electric motor and hydraulic lines"
1 2
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6.2.2 Setting rotational direction of motor
DANGER!The rotation of the motor must only be changed by a qualifiedelectrician.
Fig. 57: Locking slot for safety lock
• Switch off the main disconnect switch and secure it against being switched on
• Open switch cabinet
• Check that all connections of the main switch are free from voltage
• On the main switch exchange phases L1 and L3
• Close switch cabinet
• Switch on main main disconnect switch
• Switch on main machine switch
• Repeat rotational direction check
If for some reason one of the electric motors is removed by an electricallyqualified person, the motor must be re-wired according to the original factoryconfiguration and the rotation of the motor checked.
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6.2.3 Checking electric motor and hydraulic lines
• Run motor approximately half an hour; this circulates the hydraulic oil and allows the by-pass filter in the oil tank to strain out possible contaminants
• Check the hydraulic lines for leaks during this time
DANGER!Switch off the machine immediately you discover any leaks on thehydraulic system. Remove the causes for all leaks immediately.
Motor overload protection
The overload relay F1 controls the star-delta combination. The overload tripis set to 0.58 of the value of the maximum motor current.
If the overload protection has shut the motor off, emergency-off is triggered.The fault lamp lights up and the message is displayed in clear text.Operational readiness is restored by actuating the release button. This buttonis located under the star-delta combination in the electric cabinet (location –see electro documentation, layout plan – E-cabinet, sheet 2).
The motor needs to be restarted by pressing the button 'Motor on'.
Checking pipe connections
The pipe connections underwent an oil leak-proof test before the machine leftthe factory. However, before the first start-up and during the initial period ofoperation all pipe connections should be observed.
ATTENTION! If leakages occur, proceed as follows:
• If the connection is a compression joint it may be retightened. The union nut is to be tightened without increased force.
• If the connection is a flange fitting, the seal must be replaced.
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6.3 Checking safety devices
After initial commissioning, at appropriate intervals, after modificationsor maintenance, check the working order of all safety devices. At eachcheck the machine must effectively shut off. The checks must be madein the sequence set out.Never work with the machine if a safety device fails during a test. Havethe safety device set in working order without delay.
Test all safety devices which protect you from danger. This includes:
– Emergency-off switch– Movable safety gates– Nozzle guard– Start key– Jam bar
6.3.1 Testing the emergency-off key
Checking • Close all safety gates and the nozzle guard.
• Set operation mode selector switch in position "Setting".
• Switch on motor.
• Switch on screw cylinder heating and mould heating.
• Actuate emergency-off key.
The motor is switched off and all machine movements stop. The heating (screw cylinder and mould) is switched off. The emergency-off lamp flashes Manual operating keys become ineffective. The message "Emergency-off key actuated" appears on the screen.
• Erasing the emergency-off function is effected by disengaging emergency-off key and actuating key "Start".
6.3.2 Checking movable safety gates
Movable safety gates
The movable safety gates are doubly secured.
a.) electromechanically via limit switches .2-S5 and .2-S6 (.2-S7* and .2-S8*) and the respective valves.
b.) electromechanically via limit switches .2-S20 (.2-S21*) and valveY 9022 with monitoring switch .2-S18.
*) rear safety gate
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To a) Safety gate protection via limit switches .2-S5 and .2-S6 (.2-S7* and .2-S8*)
Limit switch .2-S5 (.2-S7*) becomes free when safety gate is closed.
Limit switch .2-S6 (.2-S8*) is activated when safety gate is closed.
Close safety gate; the message "Safety gate open" erases after key "Start" isactuated.
The limit switches .2-S5 and .2-S6 (.2-S7* and .2-S8*) are additionallysecured "via time": They must be actuated in quick succession. Whenopening a safety gate the corresponding limit switch is activated and triggersthe safety function via contactors .2-K 14 / .2-K14 A and valves Y 8007,Y 9007, Y 9008, Y 9017, Y 7008 and Y 8025 (for K-TEC 155, S-version andoption for K-TEC 40 - K-TEC 110).
*) rear safety gate
To b) safety gate protection via limit switch 2-S20 (.2-S21*)
When a safety gate is opened the corresponding limit switch is actuated andtriggers the protective function via valve Y 9022. The piston position of thisvalve is in turn monitored by limit switch .2-S18.
Front safety gate:
Here, both the front and rear safety gates must be closed. Safety gaterelease must only take place after both safety gates have been closed andthe "Start" key was actuated.
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Start up procedure
Checking • Set operation mode selector switch in position "Setting"
• Start motor
• Open safety gate
• Close safety gate
• Actuate key "Start" (safety gate release)
• Press key "Close mould":
Mould closes!
• Open safety gate during closing movement by hand:
Closing movement stops! The fault message "Front safety gate open" is displayed
ATTENTION!Repeat checking process with rear safety gate! This requires a secondperson, to open the rear safety gate.
6.3.3 Nozzle guard
Secured by limit switch .2-S9. Limit switch .2-S9 becomes free when nozzle guard is closed.
Close safety gate; the message "Safety gate open or unit safety" erases afterkey "Start" is actuated.
During opening limit switch .2-S9 is actuated and triggers the safety functionvia contactor .2-K 15 und die Ventile Y 9001, Y 9002, Y 9011, Y 9020 (forK-TEC 40 - K-TEC 110), Y 7008 (for K-TEC 155) and Y 9014.
Checking • Put operating mode selector switch in position "Manual"
• Closing mould, clamping force is built up
• Actuate key "injection unit forward" or key "injection"
• Open nozzle guard
• When nozzle guard opens the following message appears: "Nozzle guard open" or "unit protection". The cycle is interrupted; movements "Injection unit forward" or "Injection" are interrupted.
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6.3.4 Key Start (safety gate release)
To obtain safety gate release, i.e. to enable start of new cycle, the "Start" keymust be actuated each time the movable safety gates have been opened andclosed. The "Start" key can be used to erase fault messages and start a newmachine cycle in operating mode "Semi-automatic" or "Automatic".
6.3.5 Jam bar (option)
The jam bar is an additional safety device to prevent mould movement whilesafety gate is open. It consists of a toothed rack which is fitted to the movingmould clamping platen and and guided by the stationary mould clampingplaten and has a pneumatically actuated locking mechanism.
When the safety gate opens the toothed rack is locked and the safetyfunction is triggered. When the safety gate closes the toothed rack ispneumatically unlocked and mould movement is released.
The position of the locking mechanism is monitored by a limit switch. Mouldmovement is only possible when this limit switch is actuated (toothed rack isunlocked). (Message: "Jam bar")
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6.4 Checking hydraulic functions
The hydraulically moved machine elements must be checked for properfunction. If during the check, a function is not carried out, the fault must befound and corrected.
Fig. 58: Operation mode selector switch
• Set operation mode selector switch in position "Setting"
Fig. 59: Machine relevant key board
1 Open mould2 Closing mould3 Injection unit return4 Plasticizing5 Ejector forward6 Ejector return
• Press key "Open mould" and keep it pressed; the clamping unit opens to maximum opening width
• Press key "Ejector forward" and keep it pressed; the ejector moves to its forward limit position
• Press key "Ejector return" and keep it pressed; the ejector moves to its rear limit position
• Press key "Injection unit return" and keep it pressed; the injection unit moves to its rear limit position
1
56
32
4
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6.4.1 Bleeding the hydraulic system
Bleeding the pump housing:
The pump housing is supplied by the manufacturer filled with hydraulic oil. Tobleed the pump housing the pump must be run at circulating pressure for5 minutes. To do this:
• Open movable safety gate (clamping unit)
• Switch on motor
Bleeding the injection cylinder
• Heat screw cylinder to working temperature
• Set operation mode selector switch in position "Setting"
• Enter value 1 in line 49.15 (screw change)
• Press key "Plasticizing" and move screw to its rear position
• Press key "Injection" and move screw to its forward position
• Repeat process
Bleeding the clamping cylinder and traverse cylinders
• Set operation mode selector switch in position "Setting"
• Actuate key "close mould" and move the moving mould clamping platen into its forward position
• Actuate key "open mould" and move the moving mould clamping platen into its rear position
• Repeat process
Bleeding the injector
• Set operation mode selector switch in position "Setting"
• Press key "ejector forward" and move ejector to its forward position
• Press key "ejector return" and move ejector to its rear position
• Repeat process
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6.5 Top up hydraulic oil
Through the start up process hydraulic oil is pumped into the previouslyempty hydraulic system; this causes the oil level to sink.
• Check oil level at oil level sight glass and top up if necessary
CAUTION
Remove oil spots from the machine immediately and thoroughly!
Dispose of oil soaked rags and oil containers immediately and properly!
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Running and operating the machine
7 Running and operating the machine
7.1 Safety
• Do not work on the machine, if you have not been adequately instructed and trained by your company and become familiar with the machine; these operating instructions are an important but not the only means for instructing.
• Never perform work on the machine for which you are not trained and qualified; this applies especially to the hydraulic and electric equipment of the machine.
• Observe the respective valid legal regulations and guidelines for occupational health and safety, even if they are not expressly stated in this manual.
• If necessary also observe the additional safety regulations of your company.
• Remember that sickness, medication, alcohol or other drugs can affect your reactions adversely to such an extent, that working safely with the machine is no longer possible.
• Never remove or bypass the machine's mechanical, electrical and hydraulic safety devices, e.g. safety guards, safety gates, safety switches, etc.
• Do not wear ties, scarves, chains or rings which could entangle with the machine.
• Work carefully and concentrated.
• Activate the Emergency-off immediately, when persons are endangered by the machine or material damage threatens. Watch for other people near the machine and care for their safety!
• Always keep the area around the machine, especially the operator terminal free from obstructions.
• Ensure that no unauthorized person gains access to the machine.
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Running and operating the machine
7.2 Installing mould and setting machine
7.2.1 Checking the mould
Before installing the mould check that it fits machine specifications:
• Check installation height, weight and mould dimensions
*Standard version
ATTENTION!Install an additional spacer plate if the mould installation height isbelow the minimum, to avoid damaging the machine!
The maximum mould weight at the moving mould clamping platen mustnot exceed 2/3 of the total mould weight. The maximum mould weight at the stationary mould clamping platenmust not exceed 1/3 of the total mould weight.
Safety devices and safety margins are designed such that the mouldsare smaller than or equal to the dimensions of the mould clampingplaten. For larger dimensions the safety margins must be checked orthe manufacturer must be consulted.
If safety devices must be modified when moulds are used which projectbeyond the mould clamping platen, the user is responsible forproviding additional safety equipment of adequate size to absolutelyprevent access to moving machine parts during machine operation.
• Checking the maximum mould installation height; the maximum mould installation height is determined by the formula
w1 + w2 = s1 - s2
where w1 = height of first mould half, w2 = height of second mould half, s1 = maximum platen distance, s2 = ejection stroke (see Fig. 60, page 3)
• Check mould clamping dimensions (see Chapter 10 "Technical data")
K-TEC 40 K-TEC 60 K-TEC 85 K-TEC 110 K-TEC 155
Min. mould installation height* 200 mm 200 mm 250 mm 250 mm 300 mm
Max. distance between platens*
550 mm 620 mm 800 mm 800 mm 950 mm
Max. permissiblemould weight
675 kg 750 kg 1200 kg 1200 kg 2000 kg
Dimensions The dimensions of the mould must be at least 2/3 of the clearance between tie bars (horizontal and vertical)
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Running and operating the machine
Fig. 60: Determining the maximum mould installation height
1 Mould clamping platens2 Mould halves3 Moulded part
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Running and operating the machine
7.2.2 Mould installation with strain rod positioning
To install moulds whose dimensions are larger that the distance betweenstrain rods, a strain rod can be repositioned.
Fig. 61: Examples of oversize moulds
Fig. 62: Strain rod fixing elements
1 Strain rod nut2 Backup plate3 Socket head screw4 Adapter sleeve
• Open clamping unit covers
• Remove cylinder screws and then remove locking plates from the strain rod ends.
• Measure the distance "x" between strain rod end and strain rod nut on both strain rod ends with callipers
• Mark the position of parts relative to each other, in order to regain the original position during re-assembly:
– nozzle side mould clamping platen to strain rod nut, for position ofstrain rod nut
– strain rod nut to strain rod (face side), for the position of the strain rod
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Running and operating the machine
• Remove paint from strain rod thread
• Disassemble strain rod nut
• Draw strain rod toward clamping side
ATTENTION! Do not draw strain rod out of the moving mould clamping platen.
• Install mould
• Coat seat of rods with anti-seize compound and lubricant (e.g. Rivolta G.W.F.compound)
• Draw in strain rod
• Install strain rod nuts and tighten so that the measured distance "x" is reached and the markings match
• Install locking plates. The locking plates must fit evenly on the strain rod end
• Tighten cylinder screws with torque wrenchM12: MA = 100 NmM16: MA = 230 Nm
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Running and operating the machine
7.2.3 Altering installation height with pressure bolt
The installation height (min. mould installation height, max. distance betweenplatens) can be altered by changing the length of the preassure bolt (seeChapter 9.2.1 "Replacing the piston rod seals; replacing the pressure bolts").
Fig. 63: Pressure bolt installed and uninstalled
ATTENTION!• Plausibility monitoring of the ejector stroke (line 52.02 see Fig. 70,
page 20) does not alter with the change of the pressure bolts, i.e. the maximum permissible value in line 52.02 (ejector stroke) relates to standard equipment on machines!
• If the maximum possible ejector stroke is used with a shortened pressure bolt, it can lead to mould and ejector damage.
When the minimum mould installation height is altered by changing thepressure bolt, the measured length of the pressure bolt must be entered inline 50.04.
Entering pressure bolt length
• Set operation mode selector switch in position "Setting"
• Put key switch in position 1
• Select screen page 50.0
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Running and operating the machine
Fig. 64: Screen page 50.0
• Actuate softkey "Pressure bolt adjustment";this activates line 50.05 for required value entry
• Enter value 1 in line 50.05.
After actuating key "ENTER" a jump to line 50.04 occurs
• Enter the measured pressure bolt length in line 50.04 to within an accuracy of 0.1 mm
• Actuate "ENTER" key
• Close mould and readjust mould installation height
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Running and operating the machine
7.2.4 Mould installation
DANGER!When moving heavy loads there is a constant danger of loads falling!
• Always observe the carrying capacity of lifting and load carrying devices (chains, slings or belts)!
• Always make sure that no persons are under a suspended load!
Preparation for mould installation
• Close safety gates and switch on machine
• Test machine safety devices
• Set operation mode selector switch in position "Setting"
• Actuate key "Pump motor on"
• Actuate key "Open mould" until clamping unit is fully open
• Actuate key "Pump motor off"
• Open safety gates
• If necessary, clean mould clamping platens
• If necessary, remove shipping brackets from ejector
• Prepare suitable lifting devices (fixed or mobile crane) and load carrying equipment (chains, slings or belts) to move the mould
• Screw cylinder heating should be switched on early to reduce set-up times as well as wear on the screw cylinder. This should be done during mould installation.
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Running and operating the machine
Correcting minimum installation height
If the mould does not have the minimum installation height, first fit a suitablespacer plate to the moving platen:
• Securely fix the spacer plate to the lifting device
• Lower spacer plate between strain rods and fix securely to the moving platen
DANGER!Fixing elements can come loose if incorrectly used.
• Screw the fixing screws at least 1.5 times their diameter into the mould clamping platen
• Subject screws to tensile stress and never bending stress
Centering the mould
It is recommended to center only on the nozzle side of the mould half.Centering on both sides could affect mould and machine tolerances, causingexcessive wear.
• If necessary, fit a suitable centering ring to the nozzle side of the mould half
CAUTION, DANGER OF COLLISION!With special centering rings, which have diameter smaller than thestandard centering diameter, it may not be possible to move tomaximum depth with the injection unit. Failure to follow this instructionmay result in damages to nozzle heater band and nozzle thermocouple.
Sequence of assembly
NoteTo avoid dirt and corrosion it is recommended to fit a sheet of oil paper between mould and mould clamping platen.
Proceed with mould installation as follows:
Install mould on stationary mould clamping platen
• Apply a thin coating of grease to the mould mounting surfaces
• Fit oil paper, smooth out and cut of excess
• Securely attach mould to lifting device
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Running and operating the machine
• Lower mould between strain rods, without damaging the rods
• Align mould to the stationary platen with the help of the centering ring; the bolt pattern of the mounting plate serves as an optical check
• Fix the mould to the stationary mould clamping platen. Observe correct length of fixing screws; screw the fixing screws at least 1.5 times their diameter into the mould clamping platen
• Close safety gates
• Actuate key "Pump motor on"
Carrying out mould height adjustment
Carry out mould height adjustment as follows:
• Set operation mode selector switch in position "Setting"
• In line 50.02 enter a setting pressure of approx. 50 bar
• Press key "Close mould", until mould is completely closed
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Running and operating the machine
• Do not release key "Close mould" (even after mould is closed)
• Actuate softkey "Mould height adjustment" ;This activates line 50.03 (mould installation height) for value entry
• Keep key "Close mould" pressed and press key "ENTER"; in this way the actual value is accepted as the required value
• Line 51.02 (mould opening stroke) is activated automatically
Fig. 66: Screen page 51: Clamping unit: Open mould, dwell time
• Keep key "Close mould" pressed and press key "ENTER"
• Release key "Close mould"
The mould height is now set. The message "Mould height not set" is erased.
Activate function "Clamping force during setting"
• Activate function "Clamping force during setting"
– Set operation mode selector switch in position "Setting"– Select screen page 50.0– Actuate key "close mould" until mould is fully closed– Do not release key "Close mould"– Activate softkey "Clamping force during setting"
Clamping force builds and the message "Clamping force active during setting" (compare clamping force actual value in line 50.18 or in the status display)
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Running and operating the machine
The message "Clamping force during setting" erases when actuating key "Open mould" or when changing to operation mode "Manual"
Installing mould on moving mould clamping platen
• Open safety gate
• Fix the mould to the moving mould clamping platen.
• Remove shipping brackets from mould
Connecting core pulls
The hydraulic and electronic equipment of the machine for core pulls isavailable as an option. If the machine is fitted with core pulls the next step isconnecting them.
NoteThe user is responsible for the installation and application of optional equipment. It is therefore not the subject matter of this description. Consult your superior for further information.
DANGER!Use only flawless and undamaged hydraulic hoses and couplings! Thesealing surfaces must be clean and oil free!
Proceed in accordance with the information of the user:
• Connect the hydraulic hoses to the pressure cylinders of the core pulls
• Connect the limit switches of the core pulls to the machine control
7.2.5 Connecting cooling water lines
If the mould needs to be cooled, the next step is connecting the cooling waterlines. Cooling water manifolds for the machine are available as an option.Special temperature control devices can also be used.
NoteThe user is responsible for the installation and application of optional equipment. It is therefore not the subject matter of this description. Consult your superior for further information.
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Running and operating the machine
ATTENTION!Make sure the cooling water hoses on the mould are coupled to theright connections.
Proceed in accordance with the information of the user:
• Connect cooling water lines to the mould; if necessary, use air pressure to check that the lines are clear
7.2.6 Connecting air pressure lines
If the machine is fitted with air pressure lines for air ejectors, the next step isconnecting the air pressure lines.
NoteThe user is responsible for the installation and application of optional equipment. It is therefore not the subject matter of this description. Consult your superior for further information.
DANGER!Use only flawless and undamaged air pressure lines and couplings! Thesealing surfaces must be clean and oil free!
Proceed in accordance with the information of the user:
• Connect air pressure lines to mould
7.2.7 Connecting mould heating
Mould heating or temperature control devices are an optional feature of themachine. If the mould is to be heated, the next step is connecting the mouldheating.
NoteThe user is responsible for the installation and application of optional equipment. It is therefore not the subject matter of this description. Consult your superior for further information.
Proceed in accordance with the information of the user:
• Connect the power supply for the heat cartridges of the mould heating
• Connect temperature sensors
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Running and operating the machine
7.2.8 Coupling ejector
When an air ejector is not used, the hydraulic ejector of the machine must becoupled with the ejector mechanism of the mould; various kinds ofmechanical couplings are used, e.g. rigid or spring loaded couplings.
NoteThe user is responsible for the installation and application of optional equipment. It is therefore not the subject matter of this description. Consult your superior for further information.
Proceed in accordance with the information of the user:
• Bridge the distance between ejector rod of the mould and the hydraulic ejector with a suitable screw; screw the screw into the thread of the ejector and secure it with a counter nut.
• Securely couple the screw with the ejector rod of the mould.
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Running and operating the machine
7.3 Setting the clamping unit
After the mould has been installed the necessary parameters for machineoperation need to be entered. This means especially strokes, speeds andpressures. For some parameters there may be standard values supplied bythe mould manufacturer and the material supplier.
7.3.1 Mould height adjustment
With mould height adjustment the zero point for mould movement, i.e. thestroke point "Mould closed", is determined and set.
• For mould installation procedure see Chapter 7.2.4
Fig. 67: Screen page 50: Setting the clamping unit
7.3.2 Setting closing speed
The closing speed can be set in three speed stages. Mould movement shouldon the one hand occur quickly, on the other softly. The switchover pointsbetween the stages are defined stroke-dependent.
• In line 50.09, enter the required stroke points for the switchover between the speed stages
• In line 50.10, enter the required speeds for the individual stages
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Running and operating the machine
7.3.3 Setting mould safety
At the end of the closing process the mould is secured, stroke dependent,with a certain pressure. The safety phase is monitored, time dependant.Mould safety should start before the guide bolts enter the guide bushes of themould.
When mould safety responds, the message "Mould safety" appears on thedisplay; the closing movement is stopped and the mould opens completelyafter monitoring time has expired, without starting the ejector.
• In line 50.11, enter the required stroke point for the start of mould safety
• In line 50.12, enter the required pressure for mould safety
• In line 50.15, enter the required monitoring time for mould safety; a guide value could be the closing time plus 0.3 to 0.5 seconds
Fig. 68: Diagram: Closing mould
Mould safety repeat, line 50.17 (option)
Up to four repeats of closing movement can be entered. The ejector isstarted. The repeat must only be switched on when renewed closing of themould does not damage the mould. If mould safety does not respond afterthe repeat of the closing movement, the machine continues to operatenormally.
v1v2
Programmedramp
Mould safety pressuredetermines the speed
Speed control Pressure control
End mouldsafety
Startmouldsafety
Pressure control is set toobtain v1 and v2
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Running and operating the machine
Two-stage mould safety (option)
A two-stage mould safety phase can be advantageous, especially for springloaded moulds which require greater force to close.
Mould safety 1: • In line 50.12, enter the stroke point for the start of mould safety 1
• In line 50.13, enter the pressure for mould safety 1
• In line 50.14, enter the monitoring time for mould safety 1
Mould safety 2: • In line 50.12, enter the stroke point for the start of mould safety 2
• In line 50.13, enter the pressure for mould safety 2
• In line 50.15, enter the monitoring time for mould safety 2
Setting clamping force
Mould closing process ends with clamping pressure build up. The optimumclamping pressure is derived from the form of the mould and the injectedmaterial.
• In line 50.16, enter the stroke point the start of clamping force build up; for mould safety the stroke point should lie as close as possible to zero, a good guide value lies at 0.1 to 0.2 mm
• In line 50.18, enter the required clamping force.
Start injection at clamping force, line 50.19(only for S-version)
When the wall thickness of the moulded parts allows, injection can beginduring the clamping pressure build up phase. This saves time and shortensthe cycle. For safety reasons, the release is first given after 30% of maximumclamping pressure has been attained.
• Should the machine first start injecting after the clamping pressure entered in line 50.18, the value in line 50.19 must be set on 0
Clamping pressure during setting
For mould installation procedure see Chapter 7.2.4
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7.3.4 Setting mould opening
Mould opening speed, stroke and force are essential for the ejection of themoulded part. The speed can be set in three stages.
Fig. 69: Screen page 51: Mould opening data and pause time
• In line 51.02, set the mould opening stroke so that the part can leave the mould without problem
• if the form of the mould makes an increased opening force necessary, enter the stroke point, up to which the increased opening force is required, in line 51.03; increased opening force always requires a reduced opening speed
• In line 51.07, enter the stroke points for speed switchover
• In line 51.08, enter opening speeds for the stages; the same values can be entered
• In line 51.12, enter the pause time up to the start of a new cycle
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Plasticizing parallel to clamping pressure release (only for S-version)
If value 1 is entered in this line plasticizing takes place parallel to clampingpressure release. Cycle time can be reduced with this parallel function.However, it is only practical if a shut-off nozzle is used.
Mould movement parallel to plasticizing (only for S-version, option)
This function is activated in line 51.10 (enter value 1) and is only practicalwith a shut-off nozzle.
7.3.5 Setting ejector
The ejector stroke should not be larger than is necessary for the ejection ofthe moulded part. The ejector stroke can, dependent on speed, slightlyexceed the set stroke. The maximum ejector stroke of the standard ejector is:
First the ejector zero point must be set, then the number, the speed and thepressure of the ejector strokes can be entered. Ejector speed and pressurecan be set in two stages for forward movement and in one stage for returnmovement (two stages, option).
• Press key "Open mould", until mould is completely open
• Set operation mode selector switch in position "Setting"
Ejector zero point adjustment
• Actuate softkey "Zero point adjustment"
• with keys "ejector forward" or "ejector return" move ejector to the desired ejector position
• press key "ENTER"; this way the actual position of the ejector is accepted as zero point
• In line 52.02, enter the ejector stroke
K-TEC 40: 120 mm K-TEC 110: 150 mm
K-TEC 60: 120 mm K-TEC 155: 180 mm
K-TEC 85 150 mm
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Running and operating the machine
Start ejector forward,Line 52.03(only for S-version)
The ejector is started between start open mould and mould opening width.
ATTENTION!The starting point must be so selected that the ejector does not comeinto contact with the nozzle side of the mould.
Fig. 70: Screen page 52: Ejector settings
• In line 52.03, enter the stroke point for the start of ejector movement
• In line 52.05, enter if the ejector should return automatically (enter "0") or should remain forward until the command for return movement is given (enter "1"); command for return movement in manual operation is given by pressing key "Ejector return", in semi-automatic and automatic operation it is given by opening and closing the safety gate and actuating the "Start" key
• In line 52.06, enter the number of the desired ejector strokes; a maximum of 9 ejector strokes are possible, entering "0" switches the ejector off
• With more than one ejector stroke, set the return stroke in line 52.07 around which the ejector returns between strokes.
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• In line 52.10, enter the stroke points "s" for speed and pressure switchover at ejector stroke; "s2 forward" cannot be entered since it corresponds to ejector stroke (line 52.02); "s1 return" cannot be entered since it corresponds to ejector zero point (line 52.04)
• In line 52.11, enter the speeds "v" for ejector stroke up to the corresponding stroke points; "v1 forward/return" is the speed up to position "s1 forward/return" etc.
Optional equipment: Ejector pressure,Line 52.12
• In line 52.12, enter the pressures "p" for ejector stroke up to the corresponding stroke points; "p1 forward /return" is the ejector pressure which is active up to position "s1 forward/return" etc.
• In line 52.14, enter, if desired, a pause time for the ejector stroke at stroke point s1; entering a "0" means no pause time
• In line 52.15, enter, if desired, a pause time between full ejector stroke and ejector return; entering a "0" means no pause time
Monitoring ejector rest position
For mould safety the ejector rest position (ejector zero point) is monitored.Mould closing movement can only take place when the ejector has returned.
If ejector rest position monitoring is switched off (line 52.16, value 1), mouldclosing movement can start without monitoring ejector rest position, i.e. theejector does not need to be in its rear rest position. If the ejector rest positionhas not been reached when mould safety starts, mould closing movement isinterrupted; the message "Ejector not in rear position" appears.
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Ejector coupling (option)
Procedure:
• Coupling ejector mechanically
• Select screen page 52.0
• Redefine ejector zero point
• Activate coupling ejector via softkey "Coupling"; this results in the ejector being returned into rest position under pressure (80 bar)
ATTENTION!The mechanics – coupling rod, coupling and thread – must be designedfor the force that results.
• On screen page 52.0 the message "Coupling active" appears
NOTE
Actuating softkey "Zero point adjustment" switches the "Coupling"function off The message "Zero point active appears".
In case of fault, e.g. falling short of zero point selected by ≥ 5 mm, themachine stops and the message "Zero point shortfall" appears.
Ejector platen safety
For ejector platen safety a limit switch is installed in the mould. If the ejectorreaches its rear rest position and the limit switch is not actuated, the message"Ejector platen safety" appears.
If the mould does not have a limit switch installed for ejector platen safety, ajumper (dummy plug) must be installed in the electric cabinet (see circuitdiagram).
Switching ejector platen safety on/off via screen (option)
• In line 52.17, enter value 1; ejector platen safety is active
• In line 52.17, enter value 0; ejector platen safety is off. In this case it is not necessary to install a jumper (dummy plug) in the electric cabinet.
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Setting air valves
CAUTION IS RECOMMENDED WITH PNEUMATICALLYACTIVATED CORE PULLERS!To prevent core movement while safety gate is open, do not operatepneumatically activated core pulls via the air valves of the machine (seealso EN 201:1997 ("Safe Moulds"). These air valves can also beactivated while the safety gate is open and would therefore allowprohibited core movement.
Adequate protective function is only guaranteed when the standardcore pulling control system is used for pneumatically activated corepulls, since it shuts down core movement while safety gate is open.
The control is prepared for four independent air valves Y9027*, Y9028*,Y9029 and Y9030.
*) = Option for E-version
In operation mode Setting the air valves can be activated via the followingkeys:
Fig. 71: Air valve keys
The air valves are set via screen page 69. Programme variations 1 to 4 areavailable for each air valve:
Programme 1: Parallel with ejector forward
Programme 2: Start with stroke point on opening of mould
Programme 3: Start with begin of cooling time
Programme 4: Start with clamping force build up
Programme 5: Start with clamping force release
Delay time,Air time
Both parameters are effective in programmes 2 to 5. Delay time begins withthe start of the corresponding air programme.
The air blast action time determines how long the air valve is to be activatedafter expiry of the delay time.
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Hot runner needle shut-off nozzle with Y9030 (programme 4)
The hot runner needle shut-off nozzle opens with start of clamping forcebuild-up or after expiry of the delay time. The hot runner needle shut-offnozzle remains open until the injection process has ended. The air blastaction time has no influence on the closing of the hot runner needle shut-offnozzle.
Editing valve designations (option)
If this function is released, the individual air valves can be edited.
• Put key switch in position 8
• Select screen page 69
Fig. 72: Screen page 69: Air valves
• Select valve designation with cursor keys(A box for required value entry must not be selected for entering text)
• Enter new designation with text keys, e. g. "Y9027" in "Air ejector"
• Actuate "ENTER" key
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Running and operating the machine
• For further editing of valve designations or ending text entry put key switch in a position lower than 8
NoteWith softkey "Loading standard texts" valve designations can be reset to factory designations
7.3.6 Centering injection nozzle
After installing the mould, it must be checked if the injection nozzle iscorrectly aligned with the sprue bushing in the mould.
ATTENTION!Damaged or non-matching nozzles can allow material to escape underhigh pressure during operation and cause damage to the mould!
• Check if the injection nozzle and the sprue bushing are undamaged and have a matching diameter.
• ensure that a suitable undamaged injection nozzle is installed to the injection unit; if necessary install a suitable injection nozzle
• Set operation mode selector switch in position "Setting"
• Actuate key "Pump motor on"
• Actuate key "Close mould" until mould is fully closed
• Press softkey "Clamping force at setting" to build up clamping force
• Put operating mode selector switch in position "Manual"
• Press key "Injection unit forward" and move injection unit close to mould
• hold a not too small piece of paper between the injection nozzle and the sprue bushing of the mould
• press key "Injection unit forward" until the injection nozzle sits against the sprue bushing; at the same time check if the injection nozzle when moving into the sprue bushing is displaced from its straight movement axis.
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ATTENTION!Do not operate the machine if the injection nozzle at contact with thesprue bushing is displaced from its straight movement axis. Align themould or the injection unit anew, to avoid damaging the machine andthe mould!
• Press key "Injection unit return" and move injection unit back
• Check the imprint on the paper: the imprints of the sprue bushing and the injection nozzle must be concentric and even
• If the imprint is not concentric, the mould or the injection unit must be re-aligned (see Chapter 5.3.4 "Aligning nozzle on sprue bushing in the mould")
ATTENTION!Be careful when setting core pulls! Wrong settings could damagemould and machine!
The "freely editable core pulling control system" allows an almostarbitrary integration of all cores, air valves and ejectors into themachine operating sequence.
The consequence of this flexibility is, however, that you as creator ofthe programme sequence are responsible for ensuring that allmovements of the programmed axes can proceed without colliding.
To avoid errors, we urgently recommend a careful examination of theprogramme sequence before programming.
The same applies to the functioning of the user-configurable inputs andoutputs (see "Configurable digital inputs and outputs" on page 112).Here, too, the free allocation of output signals to external signals andinternal machine signals can be determined by the user.
Ferromatik Milacron accepts no responsibility for damages to themachine and for damages resulting therefrom, which are caused byincorrect setting of the programme sequence.
The hydraulic and electronic equipment for core pulls is an additionalequipment of the machine. The machine can operate up to four coresindependent of each other. The corresponding screen pages can only beselected after the installation of the additional equipment.
7.4.1 General description
The freely editable core puller is laid out for 4 (8) cores and 4 air valves.Additionally, the machine ejector can be inserted into the sequence as acore 9. The created core-pulling programme with its machine data can bestored on data carriers (EEPROM/Disk).
Before starting to programme the core puller, the sequence must be carefullyprepared. The core puller form could be a possible help. The user should befamiliar with the operation of the input unit (IQT) (operating manual seeChapter 4)
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7.4.2 Filling in core pulling form
The input sequence determines the programme sequence. If several coresare programmed under the same starting point, the cores will be activatedsequentially.
If a further core is inserted under a core and the sequence activated parallelup to intermediate/end position, the core moves parallel to the pre-core.
If several air valves are inserted under the same starting point or core, the airvalves will start parallel.
During the cycle, core movement can be started and returned as often asrequired. Cores which have been started have to be returned in the samecycle.
The plausibility of the input is checked before being accepted into themachine sequence. If the sequence is not plausible, a reference to the inputerror appears.
With directional valves, which are to be activated in one direction only, thereset must be activated by a time of 0,01 sec in column tA/Ü.
Air valves are not checked for plausibility.
NoteA blank form as master copy can be located: see Chapter 7.4.15 "Core puller form".
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Fig. 73: Core pulling form with example
60.0 CORE PULL: all cores CORE PULLER FORM
1 Core pull No. Print programme
2 Core pull in =1 out =0 Monitoring during setting on =1 off =0
K1 K2 K3 K4 K5 K6 K7 K8 K9
4 Initial position of cores on=0 moved in=1 moved out=2
Expected position moved in=1 moved out=2 on interm. pos.=3 not active=4
Current core position out=0 moved in=1 on interm. pos.=3
0 0 0 0 0 0 0 0 0
p v S s1 s2 ta/Ü L tV M tRProgramme sequence bar % mm mm sec sec n sec
0 Parallel mould closing with starting point ... ... . 300 0 ..,.. . ..,.. . ..,..1 K1 moving in end position 100 50 e ....,. ....,. ..,.. 1 ..,.. . ..,..2 K2 moving in end position 100 100 e ....,. ....,. ..,.. 1 ..,.. . ..,..3 After clamping pressure build up ... ... . ....,. ....,. ..,.. . ..,.. . ..,..4 K3B Y9037 end position 150 50 t ....,. ....,. 0,3 1 ..,.. . ..,..5 K4B Y9039 pa. End position End position 150 50 t ....,. ....,. 0,3 1 ..,.. . ..,..6 With start injection stage ... ... . ....,. ....,. ..,.. . ..,.. 1 ..,..7 L3 needle open ... ... . ....,. ....,. ..,.. . ..,.. . ..,..8 End injection ... ... . ....,. ....,. ..,.. . ..,.. . ..,..9 L3 needle closed ... ... . ....,. ....,. ..,.. . ..,.. . ..,..10 With cooling time ... ... . ....,. ....,. ..,.. . ..,.. . ..,..11 K3A Y9038 end position .150 60 t ....,. ....,. 0,3 1 ..,.. . ..,..12 K4A Y9040 pa. end position End position 150 60 t ....,. ....,. 0,3 1 ..,.. . ..,..13 After clamping pressure build up ... ... . ....,. ....,. ..,.. . ..,.. . ..,..14 L1 nozzle side in ... ... . ....,. ....,. 3 . 0,2 . ..,..15 Parallel mould opening with starting point ... ... . 100 0 ..,.. . ..,.. . ..,..16 K2 moving out end position 100 100 e ....,. ....,. ..,.. 1 ..,.. . ..,..17 K1 moving out end position 100 100 e ....,. ....,. ..,.. 1 ..,.. . ..,..18 With start ejector ... ... . ....,. ....,. ..,.. . ..,.. . ..,..19 L2 air ejector ... ... . ....,. ....,. 0,2 . ..,.. . ..,..20 L4 Y9030 out ... ... . ....,. ....,. 1 . ..,.. . ..,..21 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..22 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..23 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..24 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..25 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..26 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..27 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..28 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..29 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..30 ... ... . ....,. ....,. ..,.. . ..,.. . ..,..
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7.4.3 Screen pages
Description of the primary page
Fig. 74: Screen page 60.0 all cores
Core pull number line 60.01 With the core pull number (max. 4 digits) various core pull sequences can bemarked (only for documentation).
Monitoring during setting line 60.02
Monitoring can be switched on or off.
WARNING!When "Monitoring during Setting" (0) is switched off, core-pull andmachine movements can be initiated with the manual function keys asdesired. The "Initial position of cores" is disregarded. Faulty operationcan cause damage to the mould.
When "Monitoring during setting" (1) is switched on, the sequential function ismonitored in setting mode. By faulty operation of the manual function keys awarning reference to the precondition is made. In screen line 60.05 the"Expected positions" are displayed for about 10 seconds.
Core pull on/off line 60.02 Switching core puller on/off is possible only in setting mode.
When the core puller is switched off, the manual function keys for cores andair valves are not active. Core positions are not monitored. The machinesequence programme disregards core and air valves.
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Running and operating the machine
When switched on, the yellow display "Core pulling program will be sent toSPS" appears. The defined core pulling/air programme is integrated into themachine sequence.
Core symbols line 60.03 Core pulls are represented by K1 (core pull 1) to K8 (core pull 8).
C9 is the machine ejector as core pull.
Ejector as core pull If the machine ejector is defined as core pull, it is no longer available asejector in the machine sequence. A "0" must be entered in screen line 52.06.The ejector is regarded as a core pull. It can be integrated into the machinesequence via the starting points.
If the ejector is not integrated into the core-pulling process, it will start asejector after expiry of the last core-pulling movement
Initial position of cores line 60.04
The initial position of cores is dependent on the defined sequential functionand is the starting point for cycle begin (mould opening width, step 0).
Core not active = 0
Core puller piston rod moved out = 1 (Odd number valves and limit switches e. g.: Y9033 (K1B) and 6B1)
Core puller piston rod moved in = 2 (Even number valves and limit switches e. g.: Y9034 (K1A) and 6B2)
Core puller piston rod intermediate position(in both directions)
= 3 The intermediate position cannot be defined as initial position.Core 1 and Core 5 as screw core have 2 limit switches for intermediate position (see table 2)
Core puller not integrated in sequence programme or has not moved after being switched on
= 4
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Running and operating the machine
Allocation of limit switches and core position
Fig. 75: Allocation of limit switches and core position
*only active as screw core and turningFig. 76: Allocation of limit switches and core position
Core pulls, air Directional valves Limit switchIntermediate position
End position
K1B Y..33 6B1V 6B1K1A Y..34 6B2V* 6B2K2B Y..35 6B3V 6B3K2A Y..36 6B4K3B Y..37 6B5V 6B5K3A Y..38 6B6K4B Y..39 6B7V 6B7K4A Y..40 6B8K5B Y..61 6B31V 6B31K5A Y..62 6B32V* 6B32K6B Y..63 6B33V 6B33K6A Y..64 6B34K7B Y..65 6B35V 6B35K7A Y..66 6B36K8B Y..67 6B37 6B37K8A Y..68 6B38K9 vor Ejector Position transducerK9 return Ejector Position transducerL1 Y9027 Air valves are not monitoredL2 Y9028L3 Y9029L4 Y9030
Limit switch for both directions
Piston rod
6B1 6B1V 6B2 Core pulling cylinder
Description of core position on screen page 60.0
Description of valves Y
70 prop. valvep or p/Q80 prop. valve Q90 directional valve..valve name
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Running and operating the machine
Core 1 and 5 have 2 limit switches each for intermediate positions duringscrew core and turning
Fig. 77: Screen page 60.0 all cores
The core position is monitored in all operating modes.
WARNING!In operation mode setting, monitoring can be switched off by entering"0" in screen line 60.02. Faulty operation can cause damage to themould.
Expected positions line 60.05
If the initial position at the start of a machine movement is not given,"Expected Positions" appears for about 10 sec in screen line 60.05. At thesame time a reference to the wrongly positioned core appears.
Programme condition line 60.08
There are three programme conditions:
– Programme modified means that the programme was changed, but asyet no plausibility test has occurred and the (old) programme in thecontrol (SPS) is no longer valid.
– Programme tested means, the programme was changed and tested,but as yet not transferred to the SPS (core puller was switched offduring test).
– Programme current means, the core pulling programme in the SPScorresponds to the programme in the input unit (IQT) and is enabled.
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Parameter symbols and dimensions in line 60.07/08 p(bar) Pressure-proportional core pull
v (%) Velocity proportional core pull whenejector is core pull, input in mm/s
S Signal of core position
e = limit switcht = Timers = displacement transducer e.g.:Ejector
s1 (mm) Start of core movement parallel to closing /opening mould.
s2 (mm) Control point moving core in/outparallel to opening/closing mould. Ifthe ejector is defined as core 9,intermediate or end position isentered.
tA/Ü (sec) Action time with air valves and corepulls via time. Monitoring time withcore pulls that are controlled by limitswitches or displacementtransducers.
L Status of core pulls after reachingintermediate/end position
M (n) Number of strokes with multi-stroke or injection stage with starting point with injection stage
tR (sec) Return time with multi-stroke
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Start of core movement
Fig. 78: Screen page 61.0: Start of core movement
Core movement starting points are released dependent on machine type.When activating "Pneumatic/electric core" (screen page 62.0, Figure 6page 20) all starting points are released. The energy supply for core pullswith additional starting points must come from an external source (air, electricpower, hydraulic unit).
The starting points are listed in time sequence. This must be consideredduring cycle sequence. If the sequence is changed, the programme test willrefer to this fault.
Exceptions:
– The starting points "Closing mould parallel with staring point" and "Atmould closing with intermediate stop" are interchangeable. The sameapplies to starting points "Opening mould parallel with starting point"und "At mould opening with intermediate stop"
– Only these 4 starting points can be set a number of timesconsecutively, to start cores and/or air valves successively at variousstroke points.
– If several cores with varying starting points are activated parallel withmould movement, each core movement must be completed beforereaching the next starting point. If core movement is not completed,mould movement is interrupted until the core movement is completed.
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Description of starting points for core and air valve movement
Before closing mould Core movement is initiated and completed before mould movement starts.
Parallel mould closing with starting point
Core movement is initiated when a certain starting point, column s1, isreached and takes place parallel to mould movement.
Parallel mould closing with control point
Core movement is initiated when a certain starting point, column s1, isreached and takes place parallel to mould movement.
A control point is entered in column s2. If core movement is not completedwhen control point is reached, mould movement is interrupted.
At mould closing with intermediate stop
Core movement is initiated when a certain stroke point, column s1, is reachedand takes place serially to mould movement.
Before clamping pressure build up
Core movement is initiated before clamping pressure build-up and occursserially. Clamping force build-up starts after core movement.
Parallel clamping force build-up
Core movement occurs parallel to clamping force build-up. Subsequentmachine functions are released after core movement.
After clamping pressure build up
Core movement is initiated after clamping force build-up and occurs serially.Subsequent machine functions are released after core movement.
Before injection Core movement is started with injection signal and occurs serially. Injection isinitiated after core movement.
With multi-component machines the text "Injection unit" is additionallydisplayed. With Softkey "Next injection unit" the injection unit appropriate forcore movement can be selected.
With start injection stagen (1 - 6)
Core movement is initiated with start injection stage (column M) and occursparallel to the injection process.
With multi-component machines the text "Injection unit" is additionallydisplayed. With Softkey "Next injection unit" the injection unit appropriate forcore movement can be selected.
End injection Core movement is initiated at the end of the last injection stage (end dwellpressure) and occurs serially.
With multi-component machines the text "Injection unit" is additionallydisplayed. With Softkey "Next injection unit" the injection unit appropriate forcore movement can be selected.
With cooling time Core movement is initiated with start cooling time and takes place parallel.Subsequent machine functions are released after core movement.
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Running and operating the machine
Before clamping pressure release
Core movement is initiated after expiry of cooling time and occurs serially.Clamping pressure release occurs after core movement.
Parallel to clamping pressure release
Core movement is initiated with start clamping pressure release and takesplace parallel. Subsequent machine functions are released after coremovement.
After clamping pressure release
Core movement is initiated after clamping pressure release and takes placeserially. Subsequent machine functions are released after core movement.
Parallel mould opening with starting point
Core movement is initiated when a certain starting point (column s1) isreached and takes place parallel to mould movement.
Parallel mould opening with control point
Core movement is initiated when a certain starting point (column s1) isreached and takes place parallel to mould movement.
A control point is entered in column s2. If core movement is not completedwhen control point is reached, mould movement is interrupted until thecontrol point is reached.
At mould closing with intermediate stop
Core movement is initiated when a certain stroke point (column s1) isreached and takes place serially to mould movement.
With mould open Core movement is initiated when mould opening width is reached and occursserially.
7.4.4 Selection of core movement type
Fig. 79: Screen page 61.1 CORE PULLS: Selection of core movement type
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There are 2 possibilities for selecting core movement type.
• Screen page 61.2 with yellow fonts, core pulls and air valve are identified by valve number (not alterable).
• Screen page 61.2 with green fonts, core pulls and air valves can be identified by text with a maximum of 15 digits
7.4.5 Input of core designations
Fig. 80: Screen page 61.2 entry of core designations
With Softkey "Switchover texts" you can switch between the text page andthe valve number
Text input can be made with double configuration of the IQT-Keys or anexternal PC keyboard.
With Softkey "Load standard texts" the original designations (screenpage 61.1) can be read in.
• Put key switch in position 3-8
• Any operating mode
• On screen page 60.0 actuate Softkey "Enter core designation". Screen page 61.2 (with yellow fonts) is installed
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• With Softkey "Switchover texts" select screen page 61.2 (with green fonts).
• Select line with cursor
• Enter core designation (maximum 15 digits).
• Actuate "ENTER" key
• For further input repeat points 5-7
With Softkey "Load standard texts" the written texts are erased and thestandard designations of screen page 61.1 for the valves (e.g.: K1B Y9033)are displayed.
With Softkey "Return to page 60" screen page 60.0 is installed. Core pull orair valve is displayed with the entered designation.
Should a valve number be displayed in place of the core/air valve designation
• On screen page 60.0 actuate Softkey "Enter core designation".
• On screen page 61.2 (with green fonts) actuate Softkey "Switchover texts"
• Screen page 61.2 (with yellow fonts) is installed
• With Softkey "Return to page 60" screen page 60.0 with valve number is installed.
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7.4.6 Serial functions
Fig. 81: Screen page 62.0 serial functions
With the serial function, specific sequence values are selected The selectionis made by choosing the line with the cursor and confirming it with Enter.
Description of lines
Movement up to intermediate position
Every core pull has a limit switch for approaching a position between endpositions. The intermediate position can be entered for one or both directions.Core pull 1 and 5 have two limit switches for intermediate positions, so thatvarying positions can be approached in both directions (Table 2 page 9).
The intermediate position can be used as follows:
• Stopping point between end positions of cores. Core pull cylinder must be pressureless. There must be an "0" in column L.
• Switchover to a second pressure and velocity stage (e.g. braking with transmissions). "Movement to intermediate position" and "Movement to end position" must be entered underneath each other in the sequence. Core pulling cylinder must be under pressure in intermediate position. There must be an "1" in column L.
Movement up to end position
The end position can be approached from an intermediate position or directwithout intermediate position.
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Parallel up to intermediate positionParallel up to end position
If several cores are allocated under one starting point, core movement occurssequentially (serially) according to allocation. If a core movement is to bestarted parallel to the pre-core, "Parallel up to intermediate position" or"Parallel up to end position" must be actuated.
Position pressurelessPosition under pressure
Determines if core pull is held under pressure =1 or pressureless =0 inintermediate/end position. With Enter the function is changed. Column Ldisplays the function.
Multi stroke from end position
With ejector as core pull, it is possible to achieve a vibrating effect. If the lineis confirmed with Enter, columns M and tR are released/blocked. In column Mthe number of strokes and in column tR the return time to the start of the nextstroke are entered.
Position signal from limit switch (end position monitoring)
With Enter an "e" appears in column S. The intermediate/end position issignalled by limit switches and indicated by light-emitting diodes in themanual function keys.
Position signal from timer With Enter a "t" appears in column S. The intermediate and end position issignalled after time has expired, column tA/Ü. There is no certainty that thecore position is always the same. Monitoring is not possible.
Position Signal from position transducer (ejector as core 9)
With Enter an "s" appears in column S. The intermediate/end position issignalled by position transducer. Stroke points must be entered in column s2.
Start delay time With Enter, column tV is released for the required core. Start of coremovement is delayed by the time entered. Again actuating Enter fades outthe function.
Action timeMonitoring time
When activating the serial function "Position signal from timer" a "t" appearsin column S. The time to be entered in column tA/Ü is the action time of thecore pull or the air valve. Monitoring is not possible.
When the serial function "Position signal from limit switch" (an "e" incolumn S) or "Position signal from position transducer" (an "s" in column S) isactivated, the tA/Ü time can be displayed with Enter. It is active as monitoringtime and must be set longer than action time. If the time expires before coremovement is completed, the programme is interrupted and a message isissued. Activating Enter fades out the function.
Pneumatic / electric core With Enter the blocked starting requirements (depending on machine type)are released on screen page 61.0. With these starting points a core pull canonly be moved with an external energy supply (air, electricity, hydraulic unit).Again actuating Enter fades out the function.
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Screw core (option) Only core pull 1 and core pull 5 can be activated as screw core. With Enter,core pull 1 or core pull 5 are displayed in magenta on screen page 60.0.
For both core pulls 4 limit switches are available. This means that eachdirection has its own intermediate position for braking. Multi-stroke is blockedduring this function. Activating Enter fades out the function.
7.4.7 Enter sequence
The entry for the sequence is made via softkeys
– Defining sequence– Modify sequence– Erase programme– Enter core designation– Testing sequence– Erase last entry– Next core– New start requirement
on screen pages 60.0 to 62.0.
After the corresponding selection the next screen page appearsautomatically. On screen page 62.0 multiple selection is possible.
Defining sequence
Before a new core-pulling sequence can be defined, an existing core-pullingsequence must be erased and the core-pull switched off in screen line 60.02
"Define sequence" mode can be exited with Clear at any time.
• Put key switch in position 3-8
• Set operation mode selector switch in position "Setting"
• Actuate Softkey "Define sequence".
Screen page 60.0 is installed in window. The guided input can begin.
• Position cursor on the required line.
• Actuate "ENTER" key
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The selected start requirement appears in window.
The full-page changes to screen page 61.1 (selection of core movementtype).
• Position cursor on desired core or air valve.
• Actuate "ENTER" key
The core or air valve under the selected start requirement appears in thewindow and the full page changes to screen page 62.0 (serial functions)
Erase last entry • Select the desired serial function with cursor and confirm with Enter
The last line can be erased with Softkey "Erase last entry".
Next core • If a further core with the same start requirement is to be activated, actuate Softkey "Next core". A return jump to full page 61.1 occurs. Repeat from step 6
New start requirement • If a further new start requirement is to be selected, actuate Softkey "New start requirement". A return jump to full page 61.0 occurs. Repeat from step 4
Complete sequence entry • Actuate Clear if entry is completed. The selection programme is exited and screen page 60.0 is installed
• "Programme modified" appears after mode "Define course" or "Modify course". A plausibility test has not yet occurred
Testing sequence
• Actuate Softkey "Test sequence". A plausibility test occurs. If the sequence is plausible, the text "Programme tested" appears. Is the sequence is not plausible, a reference to a faulty entry appears
Air valves are not included in the plausibility test!
Sending programme to SPS
• When the programme is tested, it can be sent to SPS. There are 2 possibilities to do this.
– Switch on core puller by entering "1" on screen page 60.02or if core pulling function was switched on during modifying or creatingthe sequence.– Actuate Softkey "Test sequence"; transmission begins with the
message "Sending core pulling programme to the SPS".
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If "Programme updated" appears in screen line 60.08, transmission to theSPS is complete and the function test can start.
• Enter required values (pressure, velocity, time, strokes etc.)
• Establish monitoring in setting mode, screen line 60.02:
1 = with monitoring0 = without monitoring
Testing function
• Bring machine and cores to initial position. Screen line 60.04 shows the "Initial position of the cores". Screen line 60.06 shows the "Actual core position". Both values must be equal. Initial position of the machine is mould opening width.
• If a machine or core movement is initiated without the cores being in the right position, "Expected positions" are displayed in screen line 60.05 for about 10 seconds and a reference to the fault is issued.
• Bringing the displayed cores into initial position:
– Check if no damage can occur– Set operation mode selector switch in position "Setting"– Press and hold down key "Core in" or "Core out" until limit switch is
triggered (LED in key lights up), or action time expires.– If "Monitoring during setting" is active, cores can block each other if
they are not in initial position. Remedy: Switch off "Monitoring duringsetting" (line 60.02, value 0). Repeat point c)
ATTENTION!Faulty operation can cause damage to the mould.
The core pulling process is integrated into the machine cycle. It can be run inoperation modes manual, semi-automatic or automatic, as soon as the corepuller is switched on with "1", in screen line 60.02.
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7.4.8 Modify sequence
If during "Test sequence" a programme fault was discovered or an additionalfunction needs to be inserted (e.g. an air valve), the programme sequencecan be modified with the Softkey "Modify sequence".
Enter function
• Put key switch in position 3-8
• Set operation mode selector switch in position "Setting"
• Actuate Softkey "Modify sequence"
Full page 61.0 with page 60.0 is installed in window
• Position cursor with Softkeys "Line forward" or "Line back" on input position in window.
• Actuate Softkey "Insert line". Line is inserted.
• Wth keys "Page forward" / "Page back" select full page 61.0 or 61.1
• Select starting point or valve with the cursor
• Actuate "ENTER" key
Line is inserted.
• With keys "Page forward" / "Page back" select full page 62.0.
• Process serial functions and confirm desired function (e.g. start delay time) with Enter
• Actuate key "CLEAR"
"Modify sequence" is ended and screen page 60.0 is installed
• Actuate Softkey "Test sequence".
If the core puller is switched on and the sequence is plausible, theprogramme is sent directly to the SPS and "Programme current" is displayed.
If core puller is not switched on, "Programme tested" is displayed
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Modifying sequence
If starting point, valve or serial function has to be modified, the programme"Modify sequence" makes this possible. The line to be modified can beoverwritten by the new input.
• Core puller switched on or off
• Put key switch in position 3-8
• Set operation mode selector switch in position "Setting"
• Actuate Softkey "Modify sequence"
• Position Cursor in window with Softkey "Line forward" or "Line back" on the line that has to be modified.
• Select the desired full page (screen page 61.0, 61.1 or 62.0) with keys "Page forward" / "Page back".
• Select line with cursor.
• Actuate "ENTER" key
If further programme parts are to be erased, repeat from step 5.
• Actuate key "CLEAR" when modifying is completed
• Actuate Softkey "Test sequence".
If the core puller is switched on and the sequence is plausible, theprogramme is sent directly to the SPS and "Programme current" is displayed.
If core puller is not switched on, "Programme tested" is displayed
Erasing line
• Core puller switched on or off
• Put key switch in position 3-8
• Set operation mode selector switch in position "Setting"
• Actuate Softkey "Modify sequence"
• Position Cursor in window with Softkey "Line forward" or "Line back" on the line to be erased.
• Actuate Softkey "Erase line"
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If further programme parts are to be erased, repeat from step 5.
• Actuate key "CLEAR" when modifying is completed
• Actuate Softkey "Test sequence".
If the core puller is switched on and the sequence is plausible, theprogramme is sent directly to the SPS and "Programme current" is displayed.
If core puller is not switched on, "Programme tested" is displayed
Erase programme
Before compiling a new core pulling sequence, the old sequence must beerased.
If the core puller is switched on, the sequence in the SPS is erasedsimultaneously with the sequence on screen page 60.0.
• Put key switch in position 3-8
• Set operation mode selector switch in position "Setting"
• Actuate Softkey "Erase program".
In the Info-window the inquiry "Erase core pulling program yes = 1 / no = 0"appears.
• Enter value "1"
• Actuate "ENTER" key
The core pulling programme is erased.
• Switch off core puller
7.4.9 Switching on core puller
After display "Programme tested" the machine and cores must be moved toinitial position.
• Put key switch in position 3-8
• Set operation mode selector switch in position "Setting"
• Switch on motor
• Generate safety gate release
• Switch on "Monitoring during setting" (line 60.02, value 1)
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NoteCore and mould movement lock each other. Movement is not possible
• Switching on core puller
• Actuate key "Move core in / out". In screen line 60.05 the "Expected positions" are displayed for about 10 sec. and in the status lines a message (e.g.: "C1 not moving because of C....") is displayed.
• Memorise or make a note of "Expected positions"
• Switch off "Monitoring during setting" (line 60.02, value 0).
ATTENTION!Faulty operation can cause mould damage.
• With keys "Move core in / out" move cores in and out in correct sequence. Keep key pressed until, "Current core position" equals "Expected core positions" in screen line 60.06.
• Move up to at least mould opening width (only if machine is not at mould opening width)
• Switch on "Monitoring during setting" (line 60.02, value 1)
• With keys "Move core in / out" move cores into initial position. If "Monitoring during setting" is active, cores can block each other if they are not in initial position. Remedy: Switch off "Monitoring during setting" (line 60.02, value 0).
ATTENTION!Faulty operation can cause mould damage.
The display "Current core position" must equal the display "Initialposition of cores".
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7.4.10 Operating modes
Mould safety If the starting points of screen page 61.0
– Before closing mould– Parallel mould closing with starting point– Parallel mould closing with control point– At mould closing with intermediate stop
are activated in the core pulling sequence, the machine does not open ifmould safety responds.
With other starting points of screen page 61.0 the machine opens up tomould opening width if mould safety responds.
Setting without monitoring
Mould movement, ejector, core pulls and air valves can be activated by touchoperation.
ATTENTION!Faulty operation can cause mould damage.
Setting with monitoring
Mould movement, ejector and core movement must occur according to thecore pulling sequence entered.
ATTENTION!Movements can block each other.
Air valves are not monitored.
Manual
Core pulls and air valves cannot be operated with keys.
If the starting points of screen page 61.0
– Before injection– With injection stage
are activated, the machine will only open when the key "Injection" is activatedbriefly after the start of the mould opening movement.
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Manual, semi-automatic, and automatic
If core movements in the core pulling sequence are activated under clampingforce, monitoring during setting operation must be switched on. Monitoringprevents the release of clamping force during switchover to operation modesetting, before the core puller has moved out.
7.4.11 Air valves
Air valves parallel to core puller
• Without action time and delay time:Air valves that are arranged under a core, work parallel to core movement.
• With delay time:As step 1., but triggering of air valve is delayed.
• With action time:As step 1., but at end of action time air valves are switched off, at the latest with start of the core reset.
• Action time and delay time: As described in steps 1.-3
Air valve on/off with starting point
• Without action timeWhen starting point is reached the air valve is switched on/off
• With delay timeWhen starting point is reached the air valve is switched on/off with the time delay in column tV.
• With action timeWhen starting point is reached the air valve is switched on/off with the time in column tA/Ü.
• Action time and delay timeWhen starting point is reached the air valve is switched on/off with the time in column tA/Ü.
Core puller as air valve If one of the cores K1 - K8 is used as an air valve function, the core pull mustbe moved via time. Switch-off occurs with action time. To pass the plausibilitytest, the core must be switched off with an action time of at least0.01 seconds.
Hot runner needle shut-off During manual injection air valves have no function. Opening the hot runnerneedle shut-off in operation mode manual is only possible by hand at the airvalve.
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7.4.12 Options
Series/parallel
Serial core pull If several cores have the same starting point, movements must run serially.
In the case of parallel setting, the oil flow divides and movements rununcontrolled. If the end position is set under pressure, the lowest pressurebecomes effective for all cores.
Parallel core pull If each core is equipped with a separate proportional part, cores can bemoved parallel to each other.
Ejector as core pull
Requirements • Ejector must be treated as a core.
• In screen line 52.06 the value "0" must be entered. The rest of the lines on screen page 52.0 have no function.
• Strokes (mm), pressures (bar) and velocities (mm/sec) must be entered on screen page 60.0 - 60.2 (depending on length of programme).
• Ejector as core pull can be started and reset repeatedly during the cycle.
If the core-pulling programme is switched of or erased, screen page 52.0 isrelevant for operating the ejector.
Screw core
Core 1 and core 5 are designed for 4 limit switches. This allows for theactivating of an intermediate and end position for each direction ofmovement. The function is activated by key "ENTER" in line "Screw core" onscreen page 62.0 (after actuating key "ENTER" font colour changes onscreen page 60.0).
Turning
General description of screen pages
The "Turning" function (screen page 57.0) can be included in the sequence ofthe freely editable core puller.
The "Turning" function can only be activated with starting point "With mouldopen " on screen page 61.0.
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Softkey"Next injection unit"
With Softkey "Next injection unit" the injection unit to be allocated to the corepulling function is selected.
This applies only to starting points:
– Before injection– With start injection stage– End injection
The turning function is activated on screen page 61.1 by selecting screen line"Turning" (under the air valves).
The core puller for turning, fixed by Ferromatik Milacron, is identified onscreen page 61.1 with "Turning" in red fonts
If turning is not activated, the core puller can be used for a normal coremovement.
If locking the turntable is necessary, the function is to be set via one of thefree core pullers (define core puller correspondingly before and after turning).
The settings for pressure, velocity, direction, status of end position and delaytime to the next working step (e.g.: ejector forward) are made on screenpage 57.0.
Operation mode turningLine 57.0.2
0 = turning switched off (only monitoring of turntable position)
Value 1 = turning right or left
Value 2 = turning in one direction only
Line 57.0.14Line 57.0.15
Column 11 = v and p the first stage for direction I
Column 12 = v and p the second stage (braking) for direction I
Column 21 = v and p the first stage for direction II
Column 22 = v and p the second stage (braking) for direction II
Direction I = core pulling key in (core pulling valve B, uneven valve No.)
Direction II = core pulling key out (core pulling valve A, even valve No.)
NoteWhen an injection unit is switched off, the injection times (screen page 41.0 and 42.0) for this injection unit continue to be taken into account during cycle sequence.
Switching an injection unit off does not affect the programme sequence.
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Including Handling in the programme sequence
Screen line 70.0.4 The value entered corresponds to the core pull No.
The core pull entered waits on the release of Handling.
7.4.13 Fault diagnosis
After the core puller is switched on and the programme has been transmittedto the SPS, "Initial core position" and "Current core position" are displayed. If"Initial core position" and "Current core position" are not equal, the coresmust be moved to their initial position with manual keys in operation modeSetting.
ATTENTION!Incorrect operation can cause mould damage.
With keys "Move core in / out" move cores into initial position.
Mould heating or temperature control devices are an optional feature of themachine. The screen pages for the fixture can only be selected after theoptional equipment has been installed.
If the mould is to be heated and the respective connections were madeduring installation, the appropriate parameters must be entered. The mouldcan have various heating zones, which can be named and set individually.The processing temperatures for the material can be determined from therespective data sheet of the manufacturer.
The mould heating has a soft start which can be activated in the control.During the start phase heating occurs slowly and gently with reduced power.
After pressing the key "Mould heating on" the mould is heated to the presettemperatures, with key "Mould heating off" mould heating is switched off.
Required values and tolerance values, messages
Required values as well as narrow and wide tolerances for the heating zonesmust be entered. When reaching the narrow tolerance values mould releaseoccurs, i.e. injection is possible, if no faults exist to prevent it. The faultmessage "Mould heating release missing" erases.
If the temperatures for one or more heating zones reach only the widetolerance values, the message "Mould zone ... outside narrow tolerance" isdisplayed; the machine continues to operate.
When exceeding the wide tolerance the fault message "Mould heatingswitched off - mould zone ... outside wide tolerance" is displayed; injection isnot possible, the machine stops automatically. Mould heating is automaticallyswitched off.
When the wide tolerance falls short, the message "Mould release missing" isdisplayed; the machine stops automatically.
During pauses it can be advantages to maintain or produce a temperaturebelow the working temperature, to allow faster reheating to workingtemperature. This temperature can also be defined as so-called reductiontemperature. It can be activated by pressing key "Reduce mouldtemperature". Mould heating can be reactivated by first pressing key "Mouldheating off" and then key "Mould heating on".
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NoteIf the machine is switched off during a fault or at the main switch without first pressing the key "mould heating off", reheating up to reduction temperature occurs automatically when the machine is switched on again.
Machine operation duringmessages
In operation modes "Semi-automatic" and "Automatic" the cycle is interruptedor not released during messages "Mould heating switched off" and "Mouldheating release missing".
In operation modes "Setting" and "Manual" the machine can be the moved inspite of mould heating messages, if no other fault prevents it.
Procedure: Setting mould heating
• Call up screen page 32
• If required, activate soft start in line 32.06 by entering "1"
• When soft start is activated, in lines 32.07 to 32.09 enter start duration, start temperature and power limit for the starting phase
• In line 32.11 enter reduction temperature; entering "0" switches reduction temperature off
Fig. 83: Screen page 32: Mould heating: Soft start and temperature reduction
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• Call up screen page 33
• In key switch position "3" the temperature control devices can be freely defined by text input
• Enter required values for temperature control devices; a required value of "0" switches off mould heating
• Fade in the columns for input of tolerances with Softkey "tolerances on/off"
• Enter tolerances for temperature control devices; tolerances which are too low are not practical
Fig. 84: Screen page 33: Mould heating: Description of temperature controldevices, required values and tolerances
• Call up screen page 34
• In key switch position 3 the hot runner can be freely defined by text input
• Enter required values for hot runners; a required value of "0" switches off mould heating
• Fade in the columns for input of tolerances with Softkey "tolerances on/off"
• Enter tolerances for hot runners; tolerances which are too low are not practical
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Fig. 85: Screen page 34: Mould heating: Description of hot runners, required valuesand tolerances
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7.5.1 Setting heating control parameters
ATTENTION!Attempt regulator compensation only if you have sufficient knowledgeof regulator technique
On screen page 39.1 the heating control parameters for the heating controldevices and mould heaters can be set. By entering the control parametersthe controller can be matched to the control stroke. The following table showshow the control stroke reacts to parameter changes.
xp reciprocal parameter for proportional increase TN follow up timeTV rate time
Procedure: • Set operation mode selector switch in position "Setting"
• Set key switch in position "1" if control parameters for mould heating are to be changed
• Set key switch in position "8" if control parameters for cylinder heating is to be changed
• Select screen page 30.0 or 33.0 or 34.0
• Select required heating zone
• Actuate Softkey "Change control parameters"; screen page 39.1 appears
Parameter Reaction
xp higher higher stability, slower fault control
xp smaller less stability, faster control of faults, possibly fluctuations
TN higher higher stability, slower fault control
TN smaller less stability, faster fault control
TV higher less stability
TV smaller higher stability
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Fig. 86: Screen page 39.1: Control adjustment
• Further controllers can be selected with Softkeys "Controller back" and "Controller forward" or by direct entry of the controller number in line 39.1.2.
• Set controller name in line 39.1.04; controller name can be freely defined
• Set function in line 39.1.05:
– Value 1: Power out put element– Value 2: Two-point controller– Value 3: Three-point
controller• For temperature measurement, enter value 1 in line 39.1.06 for all
heating controllers used.
• Enter control parameters in line 39.1.08 to 39.1.17
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Examples: Relationship between parameter set and control stroke characteristics:
Two-point controller, very fast (cartridge with integrated sensor)
Standard parameter (mould heating)
TN 370
TV 82
xpH 26,2
switching duration 5,5
TN 64
TV 14
xpH 5,2
switching duration 4,5
TN 10
TV 2
xpH 4,8
switching duration 0,5
TN 69
TV 15
xpH 5,4
switching duration 5,0
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7.5.2 Automatic control parameter determination
Automatic control parameter determination saves manual, time-consumingdetermination xp, TN, TV. The proportional range Xp and the switchingduration can be set differently for heating and cooling. Control parameterdetermination can be used purely for heating controllers or also for heating/cooling controllers. For heating zones which have a temperature variationhigher than 6/s, technical changes for controlling the stroke are necessary.
The control parameters can be carried out individually for each controller(individual optimization).
Coupled control circuits or control circuits which are to be handled in commoncan be optimized as control block. Here the coupled control circuits aresimply handled as a control block and optimized.
Prerequisite The temperature difference between required and actual value of eachcontroller must be at least 100°C.
Individual optimization
• Set operation mode selector switch in position "Setting"
• In line 39.01, enter the number of the controller to be optimized, or select a controller via Softkeys "Controller forward/return"
• In line 39.08, enter required temperature value
• In line 39.09 enter value "1" to integrate the controller into the block of controllers to be optimized
• Enter value "1" in line 39.11 to start optimization
• Switch on heating
The parameters determined are displayed on screen when optimization iscompleted.
• Enter value "1" in line 39.18 to take over the parameters determined
• Enter value "1" in line 39.18 to reject the new parameters
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Block optimization
• Set operation mode selector switch in position "Setting"
• To define control block
– enter controller number in line 39.01– In line 39.08, enter required temperature value– To integrate the controller into the block of controllers to be optimized,
enter value "1" in line 39.09– Repeat process until all controllers to be optimized are integrated into
the control block• Enter value "1" in line 39.11 to start optimization
• Switch on heating
As soon as block optimization is finished, the newly determined parametersfor the controller selected in line 39.01 are displayed on the screen.
• Enter value "1" in line 39.18 to take over the parameters determined for all controllers integrated into the block
• If value "0" is entered in line 39.18, the determined parameters are rejected
Erase controller from block • Enter controller number in line 39.01
• Enter value "0" in line 39.09, i.e. the corresponding controller is erased from the block
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7.6 Setting the injection unit
7.6.1 Setting cylinder heating
Basis
The suitable processing temperature for the material can be determined fromthe manufacturer's data sheet. Standard values can be called up via Helptexts
After actuating key "Cylinder heating on" the screw cylinder is heated to thetemperature set, actuating key "Cylinder heating off" switches cylinderheating off.
Under screw cylinder graphics on screen page 30.0, duty cycle (ED),required and actual temperatures and tolerances are allocated to eachheating zone.
Control adjustment for cylinder heating can be made in key switch position 8(for procedure see Chapter 7.5).
WARNING!There are hot surfaces near the screw cylinder.
The cover over the heating section of the screw cylinder must not beremoved. Failure to follow these instructions can lead to injury and/ormachine damage.
ATTENTION!The heater bands must fit snugly to the cylinder for efficient heattransfer. If plastic material enters the heater bands they will bedamaged.
Fig. 87: Seating of the FeCuNi sensors
Temperatures are measured with FeCuNi sensors (thermal elements).Ensure they are seated correctly.
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Required values and tolerance values, screw release
For the processing temperature, required values as well as narrow and widetolerance values must be entered. When reaching the narrow tolerancevalues and after a delay time of four minutes, screw release occurs, i.e.plasticizing and injection is possible. In line 30.18 screw release delay timei.e. the remaining time to screw release is displayed. A delay time of fourminutes is not enough if the screw cylinder is heated from a cold state; afterscrew release is given a further 15 minutes (small screws) to 30 minutes(large screws) must expire.
ATTENTION!If the protective function of "Screw release" is bypassed, through inputof required temperature values which are too low and do notcorrespond to the recommended processing temperature and input oftolerance bands which are too high, damage to the plasticizing unitcould ensue.
Ferromatik Milacron is not liable for damages to the plasticizing unitcaused through bypassing the protective "Screw release" function.
If a heating zone is completely switched off with required value entry 0,it is ignored during thermal soak time.
Messages
If the temperature reaches only the narrow tolerance values, the message"Heating zone outside narrow tolerance" is displayed; the machine continuesto operate. If temperatures are outside the wide tolerance the message"Screw release missing" is displayed; plasticizing and injection are notpossible, the machine stops automatically. At temperatures above the widetolerance the heating switches off automatically.
Temperature reduction
During pauses or if machine monitoring responds it can be advantageous tomaintain or produce a temperature below the processing temperature, so thata reheating to processing temperature can take place faster and the screwcylinder is protected from damage. This temperature can also be defined asso-called reduction temperature. Temperature reduction can be activated byactuating key "Reduce cylinder temperature" or via the automatic machineshutdown after motor shutdown delay time has expired. Cylinder heating maybe restarted by actuating key "cylinder heating on".
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NoteIf the machine is switched off during a fault or at the main switch without first pressing the key "Cylinder heating off", reheating up to reduction temperature occurs automatically when the machine is switched on again.
• In line 30.11 enter the required temperatures (max. 350°C for the heating segments of the screw cylinder
• In line 30.11 enter the required temperature for the hopper feedthroat; the ideal temperature depends type and dryness of the material, however it must not exceed 80 °C
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ATTENTION!By entering required value of "0" the heating segment is switched offcompletely; during screw release this segment is then not taken intoaccount.
• Fade in screen pages 30.14 to 30.17 with softkey "Tolerance on/off"
• In line 30.14 to 30.17, enter permitted temperature tolerances; too low a tolerance is not practical
ATTENTION!When processing polycarbonate always use a suitable reductiontemperature! The reduction temperature must not be switched off withthis material.
• In line 30.19 enter reduction temperature; entering "0" switches reduction temperature off
A graphic overview of temperatures in cylinder and feed throat can be fadedin with the softkey "Required/actual graphic". With other softkeys, the graphiccan be scaled to specific temperature areas and display the enteredtemperature tolerances.
Nozzle retraction is determined via nozzle retraction time (line 49.10) andnozzle return speed (line 49.12).
Nozzle speed / nozzle holding pressure
S-Version Nozzle speed and holding pressure for KTEC S-series injection mouldingmachines are set at the factory. Nozzle speed and holding pressure whichcan be controlled via the screen is an option.
Standard version Nozzle speed (line 49.11 and 49.12) and holding pressure (line 49.13) onstandard K-TEC injection moulding machines can be controlled via thescreen. The nozzle holding pressure entered in line 49.13 must always beslightly higher than the pressure value set at pressure switch .5-F1. If this isnot observed, pressure switch .5-F1 does not switch and the machine stopson step 16. The fault message "nozzle holding pressure not reached"appears. The pressure switch .5-F1 is preset at the factory to 100 bar.
ATTENTION!A safe ladder or safe steps must be used when setting the pressureswitch.
• In line 49.13, enter nozzle holding pressure
• Set operation mode selector switch in position "semi-automatic" or "automatic"
• Actuate key "Start" to initiate the cycle
• Set pressure switch .5-F1 with hexagon socket wrench so that the machine stops on step 16 (fault message: "nozzle holding pressure not reached")
• Then set pressure switch .5-F1 so that it just switches, i.e. the fault message "nozzle holding pressure not reached" erases and the cycle continues. Pressure switch .5-F1 is now set on the value entered in line 49.13.
• Increase the value in line 49.13 by 5 to 10 bar so that the pressure switch operates faultlessly.
For S-versionoption,
The reduced nozzle holding pressure during mould open is set in line49.14. This means: The traverse cylinders of the injection unit do not becomepressureless when the mould opens; the injection unit is held with thereduced nozzle holding pressure entered in line 49.14.
Line 49.02, value 0
Function: Nozzle retraction takes place immediately after injection.
Application: Only possible with shut-off nozzle
Line 49.02, value 1, line 49.09, enter value
Function: Nozzle retraction delayed after injection.
Application: Through time-controlled nozzle retraction the heat transfer from the nozzle tothe sprue bushing is precisely controlled. Retraction before the end ofplasticizing can lead to material escaping from the open nozzle.
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Line 49.02, value 2, line 49.09, enter value
Function: Nozzle retraction delayed after plasticizing
Application: Preventing material escaping from the open nozzle. Delay time is so selectedthat the compression in the front of the screw is released.
Line 49.02, value 3
Function: The nozzle always remains in the forward position. There is no loss of cycletime since there is no nozzle movent. Delay time for nozzle retraction(line 49.09) is not taken into account.
Application: With hot runner moulds, tab moulds, and generally when good heat insulationis required against mould cooling systems. If necessary, also to preventcobwebbing.
Line 49.02, value 4
Function: Nozzle retraction during faults. The nozzle always remains in the forwardposition. There is no loss of cycle time since there is no nozzle movement.Nozzle retraction delay time (line 49.09) is taken into account during a faultand the nozzle retracts according to the set nozzle retraction time(line 49.10).
ATTENTION!In connection with the automatic machine shut-down (line 80.12), forcorrect retraction of the nozzle in case of a fault a higher value must beentered for motor shut-down delay time (line 80.13) than for nozzleretraction time (line 49.10).
Application: In case of a fault the nozzle retracts and relieves the hot runner.
Line 49.02, value 3, line 49.14, enter value
Function: Reduced nozzle holding pressure during mould open (option). When themould opens the traverse cylinders of the injection unit do not becomepressureless but the nozzle is held with the reduced nozzle holding pressure.
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7.7 Setting plasticizing process
7.7.1 Basis
The material is plasticized by heating the screw cylinder and by the friction ofscrew movement, which depends on screw rpm. The material weight of themoulded part is determined by plasticizing stroke/plasticizing volume, screwdiameter, back pressure and material density. Plasticizing can take placeparallel to mould opening movement (see Chapter 7.3.4 "Setting mouldopening").
7.7.2 Stroke or volume dependent parameters
The input of parameters for plasticizing and injecting can be done on thebasis of stroke or volume, e.g. plasticizing stroke in mm or plasticizing volumeccm; during switchover both values are directly converted into the other one.Plasticizing can occur in four individually settable stages with different screwrpm and back pressure.
Entry/display of plasticizing and injection parameters can occur stroke orvolume dependent (e.g. plasticizing stroke in mm or plasticizing volume inccm).
• Put key switch in position 1
• Select screen page 40
• Select type of entry via Softkey "Display stroke/volume" or "Display hydraulic / specific".
By actuating Softkey "Display stroke/volume"
– the dimensions change from mm or mm/s into ccm or ccm/s orreverse.
– the dimension for screw rpm from 1/min to mm/s and reverse.By actuating Softkey "Display hydraulic./specific"
– the display for injection, back-, and switchover pressures changesfrom "Pressure, hydraulic " into "Pressure, specific" and reverse.
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Fig. 91: Screen page 40: Plasticizing and cooling time, basic unit: volume
Fig. 92: Screen page 40: Plasticizing and cooling time, basic unit: stroke
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• In line 40.02, enter plasticizing stroke or plasticizing volume; this determines the material quantity necessary to fill the mould
• In line 40.05 enter the switchover points for switchover to the next plasticizing stage; the plasticizing stroke/volume entered in line 40.2 is automatically entered in the last column.
7.7.3 Screw r.p.m.
Higher screw r.p.m. means higher friction and higher friction heat in the screwcylinder, which speeds up plasticizing; however, it increases wear. Therefore,making use of cooling time for plasticizing recommends itself.
Screw r.p.m. can remain constant during the whole plasticizing process(plasticizing without ramp) or reduced toward the end of the plasticizingprocess (plasticizing with ramp).
• In line 40.06 enter screw rpm or speed for the corresponding plasticizing stages, equal values can be entered.
• With Softkey "Plasticizing ramp on or off" switch plasticizing ramp on or off.
Fig. 93: Diagram: Plasticizing process – approaching end position
Optional equipment:Switchover to increased screw torque
• By means of the softkey "increased torque" (option) a switchover to a higher screw torque at a lower screw speed can be effected. A message appears on the screen indicating that the increased screw torque is active.
Screw r.p.m.
plasticizing stroke
Screw r.p.m.
plasticizing stroke
with ramp without ramp
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Fault during screw speed measurement (only for S-version)
During failure of screw rpm counter the plasticizing process is interrupted andthe message "Screw rpm counter unit 1 interrupted". A defective rpm countermay be the cause. If this fault occurs screw rpm control is no longer active.Plasticizing is still possible without screw rpm control. To do this:
• Actuate key "Start" to erase the message
• Put operating mode selector switch in position "Manual"
• Actuate key "Injection"
• After releasing key "Injection" plasticizing continues without screw rpm control
To rectify the fault (reactivate screw rpm control):
• Put key switch in position 8
• Select screen page 89.3
• Actuate softkey "Refresh"
7.7.4 Back pressure
Back pressure improves homogenization of the form mass. A low backpressure of 4 to 5 bar (hydraulic) is adequate as a rule, but a higher valuecould be necessary depending on the material. The manufacturersrecommendations serve as a guide. In manual operation back pressure isautomatically reduced to zero, if no other value was entered. Back pressurevalue during manual operation must not exceed the resistance of the opennozzle.
• In line 40.07 enter backpressure for the corresponding plasticizing stages, equal values can be entered.
ATTENTION!In manual operation do not set the back pressure higher than theresistance of the open nozzle since it will cause material to leak out ofthe nozzle.
• In line 40.08, enter back pressure for manual operation; This value will be used in manual operation instead of the value entered in line 40.07
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Screw suck-back
The screw suck-back relieves the mould hot runner and the front area of thescrew. Screw suck-back can occur before or after plasticizing or at bothtimes. To avoid streaking in the moulded part a minimal stroke should be set.
ATTENTION!Keep the screw suck-back stroke and speed minimal to avoid faults inthe moulded part.
• In line 40.09, enter the required screw suck-back before plasticizing; "0" switches screw suck-back off
• In line 40.10, enter speed for screw suck-back before plasticizing
• In line 40.12, enter the required screw suck-back after plasticizing; "0" switches screw suck-back off
• In line 40.13, enter speed for screw suck-back after plasticizing
7.7.5 Backpressure relief or screw end position control (only for S-version)
Screw end position control, line 40.14(S-version)
Screw end position control counteracts this phenomenon and holds the screwin its defined end position. The melted mass compressed by the backpressure in front of the screw, could cause the screw to drift away.
In order to avoid the plasticized mass from overflowing the nozzle, the use ofa shut-off nozzle is recommended when screw end position control isswitched on (line 40.14, value 1).
• In line 40.14, switch screw end position control on or off
Back pressure relief,Line 40.14
The injection cylinder is switched pressureless after plasticizing so that thecompressed form mass can be relieved. When using a hydraulic shut-offnozzle the back pressure relief can be switched off.
• In line 40.14 switch back pressure relief on or off
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7.7.6 Hydraulic shut-off nozzle (option)
Hydraulic shut-off nozzle continuously open
Should the hydraulic shut-off nozzle remain continuously open, or if an opennozzle is used, enter value 0 in line 40.16.
Nozzle shut-off • Enter value 1 in line 40.16.
The hydraulic nozzle opens with start of injection and closes at the end of thelast injection/dwell pressure phase.
Note: The hydraulic nozzle opens:
• at intrusion
• at screw suck-back before plasticizing; (at screw suck-back after plasticizing the hydraulic nozzle remains closed)
• at emergency-off
• when motor is shut down
• when heating is shut down
• at temperature reduction
• during power failure
• during switchover to setting mode
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Setting the hydraulic pressure for activating the hydraulic shut-off nozzle
Pressure reduction valve DV21
The hydraulic pressure for activating the hydraulic shut-off nozzle can be setat the pressure reduction valve DV21. To avoid damaging the mould anespecially sensitive pressure setting of the DV21 is required in the case ofinternal and external needle shut-off nozzles. The DV21 is located onhydraulic block 2 (injection unit) is set at the factory:
• to 100 bar in case of rotary shut-off nozzles
• to approximately 30 bar in case of needle shut-off nozzles
Material escaping from a shut-off nozzle can have the following causes:
• The mechanical setting of the actuating lever for the hydraulic shut-off nozzle is not correct
• Insufficient pressure for closing the hydraulic shut-off nozzle. If, e.g. high pressure is used for plasticizing, it can back-activate the shut-off nozzle and cause material to escape. By raising the pressure on the DV21 sufficient nozzle shut-off pressure can be obtained.
ATTENTION!Needle shut-off nozzles require a sensitive pressure setting at thepressure reduction valve DV21.
Failure to follow this instruction may result in damages to machine andmould.
Procedure • Install the pressure gauge which has been supplied to the connection on the DV21 (fixed pressure gauge = option)
• Loosen the counter nut on the setting screw of the DV21
• Switch on motor
• Set desired pressure with the adjustment screw on the DV21
• Secure with counter screw after adjustment on the DV21 has been made.
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7.7.7 Plasticizing delay
If cooling time is very long, the form-mass in front of the screw can bedamaged by being heated for a long period. If lengthening plasticizing time,e.g. reduced screw rpm, is not enough to avoid this, plasticizing start can bedelayed and first started during cooling time.
• In line 40.17, enter the required plasticizing delay
7.7.8 Intrusion
The injection volume of the machine can be increased above the measure ofthe injection volume of the injection unit by Intrusion. For this plasticizing isdone with nozzle held and with screw rpm n2, so that the form-mass ispressed into the mould before the actual injection process begins. Cycle timeis extended accordingly. The amount of intruding form mass depends onmaterial consistency and resistance in the mould.
• In line 40.18 enter the required intrusion period; "0" switches intrusion off
7.7.9 Cooling time
With end of dwell time cooling time starts. Cooling time must be long enoughto allow for proper extraction of the moulded part. During cooling time newmaterial can be plasticized.
• In line 40.19, enter cooling time
The actual value in this line indicates the remaining cooling time
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7.8 Setting the injection process
The injection process can be subdivided into two to six (with optionalequipment: up to twelve) injection stages with different injection velocities anddifferent injection pressures. The change in stages of speed and pressurecan be necessary due to mould form and material characteristics. Goal isoptimum filling of the mould and excellent part characteristics.
Switchover to the next stage occurs stroke, time, or pressure-dependent. Theactual values are displayed on screen. The criterion reached first triggers theswitchover; the triggering value is displayed in violet during operation at theend of every injection stage. The last injection stage (dwell pressure) occursonly time-dependent. After the last injection stage the cushion is displayed onscreen.
The switchover can occur through injection unit parameters or mouldparameters (mould cavity pressure dependent switchover). For this themould must be fitted with a pressure or power transducer and the machineretrofitted with a charge amplifier.
7.8.1 Number of injection stages
The number of injection stages selected should not be higher thannecessary.
• Select screen page 41
Fig. 94: Screen page 41: Injection parameters, here with six injection stages
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• In line 41.01, enter required injection stages
• In line 41.02, the value entered in line 40.02 for the plasticizing volume or plasticizing stroke (switch over with softkey "display stroke/ volume") is displayed
7.8.2 Injection pressure
This pressure is maximum pressure which is only reached when noswitchover to the next injection stage occurs.
• Enter the required injection pressure p1, p2 etc., for all injection stages. The pressure set must be adequate to overcome the resistance in the mould
By actuating Softkey "Display hydraulic./specific"
– the display for injection, back-, and switchover pressures changesfrom "Pressure, hydraulic" into "Pressure, specific" and reverse.
• When stroke or pressure-dependent switchover is required, this value must be higher than the actual pressure during injection
• When time-dependent switchover is set, this value acts as limit value
• In the last injection stage (dwell pressure) this value acts as limit value
7.8.3 Injection speed
This speed in mm/s or ccm/s (switchover with softkey "display stroke/volume") is maximum speed, which is only reached when no switchover tothe next injection stage occurs.
• Enter the required injection speed v1, v2 etc. for all injection stages
7.8.4 Injection time, time-dependent switchover
This time is maximum duration, which is only reached when no switchover tothe next injection stage occurs.
For time-dependent switchover, set switchover pressure and switchover pointso that they are not reached before expiry of injection time.
• Enter the required injection time t1, t2 etc. for all injection stages
This pressure is maximum pressure which is only reached when noswitchover to the next injection stage occurs. The switchover pressure mustnot be higher than injection pressure.
For pressure-dependent switchover, set injection time and switchover pointso that they are not reached before switchover pressure is reached.
The actual pressure of the previous injection stage must be lower than theswitchover pressure entered here, otherwise directly after switchover to thisinjection stage the existing switchover pressure is transferred to the nextinjection stage.
Pressure-dependent switchover in the first injection stage should be avoided,since a clogged sprue could lead to reaching the switchover pressure tooquickly and the first injection stage is skipped.
If pressure-dependent switchover is to take place in a number of successiveinjection stages, the switchover pressure from stage to stage must beselected higher.
• Enter the required switchover pressure pu1, pu2 etc. for all injection stages
7.8.6 Switchover point, stroke-dependent switchover
This switchover point in mm stroke or ccm injection volume (switchover withSoftkey "Display stroke/volume") is a limit point which is only reached whenno switchover to the next injection stage occurs.
For switchover at the selected switchover point set injection time andswitchover pressure so that they are not reached before switchover point isreached.
• Enter the required switchover point s1, s2 etc. for all injection stages
For mould cavity pressure-dependent switchover the mould has to beequipped with a pressure or force transducer and the machine has to beretrofitted with a KISTLER charge amplifier, type 5039A222. Mould cavitypressure-dependent switchover can take place only in one and not severalinjection stages.
• Put key switch in position 1
• Set operation mode selector switch in position "Setting"
• In line 43.05, enter type of transducer (pressure or power transducer)
• When using a pressure transducer, enter sensor sensitivity (min. 2.000 pC/bar, max. 9.999 pC/bar) in line 43.08
• When using a power transducer, enter pin diameter in line 43.10 and sensor sensitivity in line 43.11; the control automatically enters the value calculated from this pC/bar (min. 2.000 pC/bar, max. 9.999 pC/bar) in line 43.08
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• In line 43.02, enter the injection stage into which the mould cavity pressure-dependent switchover should take place
Now the cursor jumps to the pre-selected injection stage. For control the display changes in this injection stage: instead of switchover pressure pu mould cavity pressure pi appears.
• Enter required mould cavity pressure
For entering tolerance the cursor jumps to the tolerance line of the pre-selected injection stage
• Enter tolerance
Switching off or changing mould cavity pressure-dependent switchover
The mould cavity pressure-dependent switchover can later be activated orswitched off for another injection stage.
• Proceed as described in the previous paragraph
• In line 43.02, enter "0", to switch off the mould cavity pressure-dependent switchover, or choose or to select another injection stage
• The cursor will now jump automatically to each screen line that requires corrections or new entries
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7.8.8 Two-colour injection
The function of both injection units during two-colour injection is set viascreen page 44.0 "Optional equipment: Multi-colour".
To enter the parameters relevant to the individual injection units, thecorresponding screen pages need to be switched over via key "Additionalinjection units". The injection unit selected is displayed in the status display(position 4).
Operating mode line 44.02 In this line the injection units are selected. Entering value 1 the respectiveinjection unit is switched on.
Operating mode nozzle movement
Line 44.08Value 1: parallelValue 2: serial
During parallel operation the start signal for nozzle movement for bothinjection units is given simultaneously. The delay times for nozzle forwardmovement entered in line 44.12 are taken into account.
During serial operation the start signal for nozzle movement fort he secondinjection unit is given after nozzle movement of the first injection unit iscompleted. The sequence set in line 44.10 and the delay times set in line44.16 are taken into account.
Line 44.10 During serial operation the sequence for nozzle movement is set in this line
Line 44.12 A delay time for nozzle forward movement can be entered in this line for theselected injection unit (key "Additional injection units").
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Operating mode injection
Line 44.14Value 1: parallelValue 2: serial
During parallel operation the start signal for injection for both injection units isgiven simultaneously. The injection delay times entered in line 44.18 aretaken into account.
During serial operation the start signal for injection for the second injectionunit is given after the injection process of the first injection unit is completed.The sequence set in line 44.16 and the injection delay times set in line 44.18are taken into account.
Line 44.16 During serial operation the sequence for injection is set in this line
Line 44.18 An injection delay time can be entered in this line for the selected injectionunit (key "Additional injection units").
NotesWhen heating is switched on with key "Cylinder heating on", only the injection unit switched on in line 44.02 (value 1) is heated.
When an additional injection unit is switched on via line 44.02 while heating is on, the heating for this injection unit is activated.
When an injection unit is switched off (value 0) via line 44.02 while heating is on, the heating for this injection unit remains activated. If the heating is to be switched off together with the injection unit, the heating must be switched off via key "Cylinder heating off" and switched on again via key "Cylinder heating on".
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Screen page 44.0,Special equipment: Multi-colour
Fig. 96: Screen page 44.0: Special equipment multifcolour
Display of injection unit selected
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7.9 Setting machine monitoring
Automatic monitoring of various operational values ensures consistently goodpart quality. When there is a deviation from the reference values, automaticmonitoring is equipped for graduated reactions, from the simple messageduring continuous production right up to machine shut-down.
The monitoring functions are switched on on screen page 80, the tolerancebands for monitoring on the following pages.
Fig. 97: Screen page 80: Setting the monitoring functions
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7.9.1 Trend diagram
Recording of actual values for tolerance monitoring and process analysis isdone on pages 82.0 to 86.0. Each page contains two block diagrams forplotting a freely selectable process value (actual value). The allocation ofwhich process variable should be recorded on which page and in whichdiagram (above or below) is made on page 81.0.
Fig. 98: Screen page 81.0: Trend diagram selection of process size
Basically all actual values from pages 81.1 to 81.5 can be selected the fortrend display via the select-mode.
Recording is done cyclic. A maximum of 82 cycles can be recorded in adiagram.
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Fig. 99: Screen page 82: Trend diagram
Softkey "Switchover process size"
(only multi-colour/multi-component injection moulding machines) With the trend diagram a total of 20 actual values can be recorded. On screenpages 82.0 to 86.0 either the actual values 1 to 10 or 11 to 20 are graphicallydisplayed. By actuating the softkey "Switchover process size" switchoverbetween these two diagrams (process size 1 to 10 or 11 to 20) occurs.
Setting of trend diagram
The setting of trend diagram is divided into 3 main steps:
• Selection of process sizes
• Setting tolerances
• Setting of actual reference values
Selection of process sizes Recording of the selected process sizes occurs on screen pages 82.0 to86.0. 2 process sizes (actual values) can be selected per side, which are thenallocated to the upper or lower diagram.
Entering actual values • Put key switch in position 1
• Select screen page 81.0
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• Select the required position into which a process value is to be entered via curser keys.
• Actuate softkey "enter actual value"
Now the screen page 81.0 is displayed in reduced size and you are now in SELECT-MODE.
Fig. 100: Screen page 81: Trend diagram in selection mode
• Select process values; to do this:
– Select one of the screen pages 81.1 to 81.5– Select the required process values via cursor keys– Actuate "ENTER" key
Now the selected process sizes are allocated to the pre-selected diagram (display in plain text and by select-code)
• Select further process sizes orto end SELECT-MODE actuate key "CLEAR"
• Select actual value to be erased via cursor keys
• Actuate "ENTER" key
• To erase further actual values or end ERASE-MODE by actuating key "CLEAR"
Setting tolerances Input of tolerances is made for
• injection parameters on screen pages 81.1 and 81.2
• screw cylinder temperatures on screen page 30.0
Setting actual reference values
Setting the actual reference value has the effect that the currently valid actualvalue is declared as actual reference value, saved and used as basis fortolerance monitoring.
It is represented by the central point of the Y axis in the trend diagram. Thesymmetric tolerance band is laid around this central point.
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The reference values can be set for
• all process sizes with softkey on screen page 81.0 or
• for each individual process size in the trend diagram on screen pages 82.0 to 86.0.
• For each individual process size on screen page 81.1 or 81.2.
1. option • Select screen page 81.0
• Press Softkey "Set reference value"
2. option • Select the screen page on which the trend diagram of the process value is found for which a new actual reference value is to be set.
• Actuate softkey "Set reference 1" to set a new actual reference value for the upper diagram or
• Actuate softkey "Set reference 2" to set a new actual reference value for the lower diagram.
3. option • Put key switch in position 1
• Select screen page 81.1 or 81.2
• Select the required process values via cursor keys
• Actuate Softkey "Set reference value"
Erasing Trend diagram
In the trend diagram on screen page 82.0 to 86.0 each individual trenddiagram can be erased. To do this:
Page 17.1 displays the time analysis of various functional processes within amachine cycle. In column "N" the times of the current macine cycle, in column"N-1" the times of the previous cycle and in column "D" the last 10 machinecycles are recorded.
Fig. 102: Screen page 17.1: Time analysis
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7.9.3 Production data
Entry of product related data serves especially to complete the data to besaved or printed as well as the value for calculating production quantity(REQUIRED/ACTUAL/REMAINING) and duration of production(REQUIRED/ACTUAL/REMAINING). Screen page 20.0 gives on overview ofproduction data. The values shown on this screen page are taken over byscreen page 21.0 or calculated from values entered on screen page 21.0.
Additionally, when writing on the data carrier the production data "Materialnumber" and "Mould number" are used in order to clearly identify the sets ofdata saved.
Fig. 103: Screen page 20.0: Overview of production data
As soon as good parts are moulded product related data can be entered onscreen page 21.0:
• In line 21.11 enter the cycle time shown in the status display
• In line 21.12 enter the required production quantity
• With multi-cavity mould enter the number of cavities in line 21.13
On the basis of cycle time, production quantity and number of cavitiesentered, the cycles, the number of moulded parts per hour and duration ofproduction (REQUIRED) are calculated.
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Fig. 104: Screen page 21.0: Input of production data, shot counter
NoteActivate special programme:
• Set operation mode selector switch in position "Setting"
• In line 21.10 enter special programme number to activate special program
• Enter required values for the sequence of the special programme (see description of special program)
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Adding shot counter and subtracting shot counter
From the reading on the adding and subtracting shot counter the currentproduction quantity (ACTUAL), good and reject parts as well as remainingproduction quantity (REMAINING) is calculated on screen page 20.0. Thecorresponding duration of production (ACTUAL and REMAINING) is alsodisplayed.
Fig. 105: Screen page 21.0: Production data
1 Adding shot counter2 Subtracting shot counter
The adding shot counter is to be used for the whole order. All machine cyclesare counted. In the status display the current stand of the adding shot counteris displayed.
The subtracting shot counter (good part counter) only counts those cycles inwhich tolerance monitoring has not responded. The current stand of thesubtracting shot counter is shown in the status display.
If a multi-cavity mould is installed, i.e. the number of cavities exceeds 1, thesubtracting shot counter shows the number of shots which correspond to theproduction quantity entered.
1 2
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At production start the adding shot counter must be erased and thesubtracting shot counter must be set. Procedure:
• Enter production quantity in line 21.12
• Entert he number of cavities in line 21.13
• Erase adding shot counter (in line 21.14 enter value 1)
• Set subtracting shot counter (in line 21.15 enter value 1)
• Starting production
Subtracting shot counter activated without automatic machine shut-down
If the production quantity is reached, subtracting shot counter on 0, themachine stops on step 63 and the emergency-off lamp blinks.
Subtracting shot counter activated with automatic machine shut-down
If the production quantity is reached, subtracting shot counter on 0, themachine shut-down programme is activated after the shut-down delay timesentered.
In both cases the message 'Subtracting shot counter =0' appears.
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The adding parts counter (shift)
The adding part counter (shift) serves as shift counter. It is set on 0 at thestart of a shift (in line 21.16, enter value 1). Starting and end time of a shiftare set on screen page 20.1. At the end of the shift the produced quantity canbe read. Every cycle is counted. From the stand of the subtracting shotcounter the good parts per shift (see screen page 20.0 and 20.1) arecalculated.
Fig. 106: Screen page 20.1: Starting and end times of the shift
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7.9.4 Recording of process data
During a monitoring period of a maximum of 24 hours, eight process actualvalues (lines 22.11 to 22.18), messages (line 22.06, value 1), stoppage time(line 22.07, value 1) and required value changes (line 22.08, value 1) can berecorded. Three recording periods per day can be defined during whichproduction data recording operates. Continuous recording over the whole daycan also be selected.
Screen page 25.0 – 25.3 contains a list of process data recorded.
25.0: Process data25.1: Messages25.2: Stoppage times25.3: Required value changes
Screen pages 22.0 and 23.0 become visible when the key switch is inposition ≥ 3.
Fig. 107: Screen page 22: Setting the protocol sequence
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Fig. 108: Screen page 23: Recording periods and printing
Activating Process data recording is activated in line 22.02. On screen page 23 arecording period or continuously running recording must be set.
Before recording the protocol memory must be erased (line 23.18, value 1).
Protocol sequence • Set key switch in a position ≥ 3.
• Select screen page 22
• Switch on process data recording (line 22.02, value 1)
• Select one of the lines 22.11 to 22.18 via cursor keys
• Actuate softkey "enter actual value"
Now screen page 22 is displayed in reduced size and you are now in so-called SELECT-MODE.
• Select actual process values, to do this:
– Select the screen page on which the required actual process valuesare found
– Select actual process values via cursor keys– Actuate "ENTER" key
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The actual process value selected is now inserted in the selected line (22.11 - 22.18).
• Insert further actual process values orto end SELECT-MODE actuate key "CLEAR"
NoteWhen entering an actual process value in lines 22.11 to 22.18 a previously selected actual value is overwritten.
Selected actual process values can be erased. To do this
– Set key switch in a position ≥ 3.– Actuate softkey "erase actual value"– Select the actual process values to be erased (lines 22.11 – 22.18)– Actuate "ENTER" key– To erase further actual process values or end ERASE-MODE by
actuating key "CLEAR"
Printing recorded data
ATTENTION!The protocol memory is erased after recorded data is printed.
The recorded process data can be printed out in various ways:
• On demand by actuating softkey "print" (line 23.13, value 0)
• Continuously (line 23.13, value 1)
• At the end of a recording period (line 23.13, value 2)
• At the end of a cycle interval (line 23.13, value 3) after expiry of the cycle number entered in line 23.11
NoteThe print layout of the protocol on the printer is set on screen page 16.2.
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Saving data
ATTENTION!Hereby the protocol memory is erased!
By actuating "Database format on disk" the recorded data in the protocolmemory can be stored as table-text-format on disk.
Before actuating this softkey it is recommended to change into operatingmode "setting" otherwise it could lead to faulty data transmission or damageto the disk drive.
Acknowledging stoppage times
Acknowledgement of stoppage times by machine operator
On screen page 24 the reasons for machine stoppage are firmly fixed. Thesecould be extended by further reasons on customer request (option).Stoppage times are only recorded when value 1 is entered in line 22.07.
Fig. 109: Screen page 24: Acknowledgement of stoppage times
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• Select screen page 24
• Select line which states the reason for machine stoppage.
• Actuate softkey "start stoppage"
• When fault is rectified actuate softkey "end stoppage"
Editing stoppage texts (option)
If this function is released, free text stating reasons for stoppage can beentered (Procedure see Chapter "Setting air valves").
NoteWith softkey "Loading standard texts" factory settings are restored.
7.9.5 Cycle time monitoring
Cycle time monitoring occurs during semi-automatic and automatic operation.The complete machine cycle is monitored. It is not possible to switch off cycletime monitoring.
• Select screen page 80
• Enter cycle time monitoring period in line 80.09 (at least 2 seconds)
• Enter tolerance for trend diagram in line 81.2.09
The machine opens and stops at mould opening width. The plasticizingprocess stops, the machine becomes pressureless. Motor and heatingremain switched on. The message "Cycle time exceeded" appears and thealarm lamp on the electric cabinet lights up.
• Remove cause of fault
• Press key "Start" to resume production
Reaction when exceeding time in STEP 19 to 63
The cycle is completed. The machine stops at mould opening width. Theplasticizing process stops, the machine becomes pressureless. Motor andheating remain switched on. The message "Cycle time exceeded" appearsand the alarm lamp on the electric cabinet lights up.
• Remove cause of fault
• Press key "Start" to resume production
If cycle time is interrupted during the plasticizing process, proceed as follows:
• Actuate "Start" key
• Put operating mode selector switch in position "Manual"
• Press key "Injection unit return" and move injection unit completely back
• Actuate key "Injection"
• Set operation mode selector switch on "Automatic" and resume production
Reaction when automatic machine shut-down is activated
When in line 80.12 the automatic machine shut-down is activated and cycletime monitoring responds, the machine opens and stops at mould openingwidth. The plasticizing process is interrupted. Motor and heating are switchedoff. The message "Cycle time exceeded" appears and the alarm lamp on theelectric cabinet lights up.
• Remove cause of fault
• Press key "Start" to resume production
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When cycle time monitoring responds at a time when the mould cannot moveopen, cycle time runs down a second time. At expiry of this time the machinestops at the position just reached. The plasticizing process stops, themachine becomes pressureless. Motor and heating are switched off. Themessage "Cycle time exceeded twice" appears and the alarm lamp on theelectric cabinet lights up.
7.9.6 Plasticizing time monitoring
The whole plasticizing process is monitored. Plasticizing time monitoring canbe switched off.
• Select screen page 80
• In line 80.10, enter monitoring time; entering "0,0" switches plasticizing time monitoring off
• Enter tolerance for trend diagram in line 81.1.03
Reaction when exceeding time in STEP 0 to 18
The machine opens and stops at mould opening width. The plasticizingprocess is interrupted. Motor and heating remain switched on. The message"Plasticizing time exceeded" appears and the alarm lamp on the electriccabinet lights up.
Reaction when exceeding time in STEP 19 to 63
The cycle is completed. The machine stops at mould opening width. Theplasticizing process is interrupted. Motor and heating remain switched on.The message "Plasticizing time exceeded" appears and the alarm lamp onthe electric cabinet lights up.
• Remove cause of fault
• Actuate "Start" key
• Put operating mode selector switch in position "Manual"
• Press key "Injection unit return" and move injection unit completely back
• Actuate key "Injection"
• Set operation mode selector switch on "Automatic" and resume production
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Reaction when automatic machine shut-down is activated
When in line 80.12 the automatic machine shut-down is activated andplasticizing time monitoring responds, the machine opens and stops in mouldopening width. The plasticizing process is interrupted. Motor and heating areswitched off. The message "Cycle time exceeded" appears and the alarmlamp on the electric cabinet lights up.
7.9.7 Plasticizing stroke monitoring
In manual operation plasticizing occurs as long as the key "plasticizing" ispressed. This makes exceeding the set plasticizing stroke possible. In thiscase plasticizing stroke monitoring responds.
Reaction without automatic machine shut-down
When the automatic machine shut-down is not activated in line 80.12 andplasticizing stroke monitoring responds, no injection process occurs; themachine opens up to mould opening width. The message "Plasticizing strokeexceeded" appears and the alarm lamp on the electric cabinet lights up.
• Remove cause of fault
• Put operating mode selector switch in position "Manual"
• Press key "Injection unit return" and move injection unit completely back
• Actuate "Start" key
• Actuate key "Injection"
• Set operation mode selector switch on "Automatic" and resume production
Reaction with automatic machine shut-down
When the automatic machine shut-down is activated in line 80.12 andplasticizing stroke monitoring responds, emergency-off occurs; motor andheating are switched off. The message "Plasticizing stroke exceeded"appears and the alarm lamp on the electric cabinet lights up.
• Remove cause of fault
• Put operating mode selector switch in position "Manual"
• Press key "Injection unit return" and move injection unit completely back
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• Actuate "Start" key
• Actuate key "Injection"
• Press key "Open mould" and move mould to opening width
• Set operation mode selector switch on "Automatic" and resume production
7.9.8 Injection parameter monitoring
Monitoring for the individual injection stages can be set independent of eachother. Basis for monitoring is a reference value and a tolerance band for thedeviation. When the tolerance band is left a message is given out.
• Select screen page 80
• In line 80.02, enter "0", to switch off monitoring, or enter "1", to switch on cushion monitoring, or enter "2", to monitor all injection parameters
• When monitoring was switched on, select screen page 81
• Press Softkey "Set reference values", to take over the actual value parameter set of a good part as reference
The maximum number of tolerance deviations directly following one anothercan be preset. Counting occurs separately for every injection parameter. Forevery machine cycle outside tolerance the meter count increases by one, forevery cycle inside tolerance the meter count is decreased by one. When theset number is exceeded the machine stops and a message is displayed. Thefunction is active only in key switch position "0".
• Select screen page 80
• In line 80.06 set the maximum number of tolerance deviations; entering "0" switches the function off, i.e. when leaving the tolerance zone a message appears but the machine is not stopped
• Messages caused by tolerance deviations can only be erased by pressing the key "CLEAR"; entry and confirmation of "0" in line 80.02 resets counter to zero
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Tolerance monitoring: Selection of process steps (multi-component injection moulding)
During multi-component injection moulding the injection process oftenconsists of three processing stages. If working with more than one injectionunit, they can be allocated to the various processing stages for tolerancemonitoring.
Number and allocation of processing stages
The number of processing stages is entered on screen page 80.01 in line 2;allocation of the injection units to the various stages is made in line 4. Morethan one injection unit may be allocated to one stage.
Reject status, process evaluation
To asses the ejected part as "Good part" or "Bad part", control evaluates theindividual processing stages. The individual processing stages for the ejectedpart are evaluated from the pre-injected part to the finished part.
Example: The injection moulding machine employed has three injection units. Themoulded part runs through two processing stages to completion. In the firstprocessing stage injection units 1 and two are used to inject the pre-injectedpart. In the second processing stage the third injection unit is used tocomplete pre-injected part.
7.9.9 Automatic machine shutdown
It serves mainly for operation without personnel. During each cycleinterruption the monitoring function can automatically (line 80.12 value 1)shut down the motor, the heating and cooling water.
Shutdown delay motor/heating
When the motor shuts down, heating also shuts down or temperaturereduction takes place. The corresponding shutdown delay time is entered inline 80.13. A shutdown valve is required for cooling water shutdown (option)
Shutdown delaycooling water
Cooling water shutdown delay time (line 80.14) should always be selectedlonger than motor shutdown delay time since screw cylinder (feedthroat)requires adequate cooling down time after heating has shut down (flow-onheat).
Line 80.1.02: Number of processing stages 2
Line 80.1.04: Processing stages - allocation (1-2)
Injection unit 1 1
Injection unit 2 1
Injection unit 3 2
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7.10 Freely composable screen pages
From the multitude of required and actual value lines a selection can becompiled on the 3 screen pages 13.0 to 13.2. It is possible to compile lines, inwhich set value changes are constantly made, on a user compiled page. Alsographic elements, e.g. trend diagrams, can be inserted in user compiledscreen pages.
The user compiled screen pages are saved when writing on data carrier.They can be read out again together with setting information (compare seeChapter 7.15 "Storing and reading of parameter sets").
7.10.1 Composing pages
• Put key switch in position 2
• Select one of screen pages 13.0, 13.1 or 13.2
• Actuate Softkey "Insert object" to get to select-mode; the screen page selected appears reduced on the screen
• Leaf through screen pages and with the cursor keys select the parameters or graphics required and confirm by pressing the "ENTER" key; in the window faded in the layout of the compiled page appears
• Press key "CLEAR", to close selection
Fig. 111: User compiled pages in select-mode
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7.10.2 Changing user compiled pages
• Select page to be changed, 13.0, 13.1 or 13.2
• Press Softkey "Insert empty line", determine empty line position with cursor key and confirm with the "ENTER" key; press key "CLEAR" when all empty lines are set
• Press Softkey "Erase object", determine object on page with cursor key and confirm erase with the "ENTER" key; press key "CLEAR" when the required objects are erased
• Press Softkey "Insert object", to insert new objects
7.10.3 Required value entries on user compiled pages
On the user compiled pages required values can also be entered in keyswitch position "0". However, the entry is protected by a password. Afterentering the password required values can be set for a period of 30 minutes.
Setting password
• Select screen page 13.0, 13.1 or 13.2
• Put key switch in position 3
• Press Softkey "Set password"
• Enter password (max. length eight letters, small and capital letters are considered
• Press "ENTER" key, to confirm password
Required value entry
• Put key switch in position 0
• Select screen page 13.0, 13.1 or 13.2
• Press Softkey "Enter password"
• Enter password
• Actuate "ENTER" key
• Enter required value; you have 30 minutes available
• Block entry again; for this press Softkey "Enter password", do not enter password and press "ENTER" key
• Erase the fault message "Wrong password entered" with the "CLEAR" key
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7.11 Freely writeable screen pages
To retain important setting information screen pages 12.3 to 12.6 can beused. They serve as "Note pad" and have no influence on machine function.The setting information can be read out from a disk or read in from a disk (seeChapter "Storing and reading of parameter sets" on page 125).
Text input • Select one of the screen pages 12.3 to 12.6
• Put key switch in position 3
• Hold "ALT" key pressed and with input keys enter any text you like
• After completing text entry press "ENTER" key to confirm entry
Setting information There is also the option of saving important setting information correspondingto a mould on screen pages 12.0 to 12.2.
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7.12 Configurable digital inputs and outputs
7.12.1 Configurable digital inputs
The four configurable digital inputs make it possible for the operator toinfluence certain machine functions by means of 24V-signals of externaldevices. These 24V-signals are put onto module A1230 (in case of multi-colour machines: on module A1230) (see circuit diagram - group 1, sheet 45).
The blocking parameters are selected on screen page 66.0 and allocated toconfigurable digital inputs 1 to 4. For this, a characteristic number from 0 to12 has to be entered in the box "Function" of the corresponding input.
If the input is energized with 24 V (box "ACT", value 1), the selected machinefunction is blocked. Only when the digital input is deactivated (box "ACT",value 0), the selected machine function is enabled.
MonitoringIf a blocked machine function should be started via a configurable digitalinput, although the corresponding input is activated, one of the followingmessages appears after 3 seconds: "Release conf. input 1 missing ", ...,"Release conf. input 4 missing".
Example:If the function "External cycle stop" is desired, the characteristic number 2"End of machine cycle" has to be entered on one of the configurable digitalinputs.
Standard configuration:
Configuration for multi-colour machines:
Digital input
Terminalon module A1230
Address/Channel
Function input on screen page 66.0 in
1 6 1/4 / 5 Line 1
2 7 1/4 / 6 Line 2
3 8 1/4 / 7 Line 3
4 9 1/4 / 8 Line 4
Digital input
Terminalon module A1230
Address/Channel
Function input on screen page 66.0 in
1 26 37 / 21 Line 1
2 27 37 / 22 Line 2
3 28 37 / 23 Line 3
4 29 37 / 24 Line 4
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Fig. 112: Screen page 66.0: Configurable digital inputs
7.12.2 Configurable digital outputs
The four configurable digital outputs make it possible for the operator totrigger external devices in dependence on certain machine functions. These24V-signals are put onto module A1330 (in case of multi-colour machines: onmodule A1250) (see circuit diagram - group 1, sheet 45).
The blocking parameters are selected on screen page 66.1 and allocated toconfigurable digital outputs 1 to 4.
For this, a characteristic number from 0 to 17 has to be entered in the box"Function" of the corresponding output (line 1 to 4).
In the box "ACT.TIME" it is determined how long the digital output remainstriggered.
– Value 0:The digital output remains activated for as long as the selectedmachine function is operating.
– Value greater than 0:The digital output is activated upon start of the selected machinefunction (box "ACT", value 1) and is deactivated after the lapse of theaction time entered (box "AKT", value 0).
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Standard configuration
Configuration for multi-colour machines
Fig. 113: Screen page 66.1: Configurable digital outputs
Digital output
Terminal onmodule A1330
Address/Channel
Function andaction timeinput on screen page 66.1 in
1 12 1/5 / 9 Line 1
2 13 1/5 / 10 Line 2
3 14 1/5 / 11 Line 3
4 15 1/5 / 12 Line 4
Digital output
Terminal onmodule A1350
Address/Channel
Function andaction timeinput on screen page 66.1 in
1 21 38 / 17 Line 1
2 22 38 / 18 Line 2
3 23 38 / 19 Line 3
4 24 38 / 20 Line 4
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7.12.3 Configurable analogue outputs (option)
The four configurable analogue outputs enable the operator to display certainprocess variables. Analogue outputs are updated every 10ms. In box "AKT"the actual value in volt given out. The unit and the scaling are faded independent on the selected function, i.e. the max. output voltage of 10Vcorresponds to the final scaling value given in the table. The analogueoutputs are wired on BNC-sockets on the side wall of the electric cabinet (seeflow diagram - group 1, sheet 46).
Process variables are selected on screen page 66.2 and assigned to the fourconfigurable analogue outputs.
• Therefore, enter a characteristic number from 0 to 11 in box "Function" of the corresponding output (line 1 to 4).
With standard graphics, the four operational parameters of hydraulicpressure actual value, (channel 1), screw stroke (channel 2), mould cavitypressure (channel 3; for this the mould must be fitted with a pressure orpower transducer and retrofitted with a charge amplifier) and hydraulicpressure required value (channel 4) can be graphically displayed at the sametime. However, process monitoring does not take place. Recording time canbe set and starts with start of injection. The graphic is displayed on screenpage 46 and serves for visual purposes only; setting parameters on this pageis not possible.
With the help of two cursor lines the exact values of a certain curve positioncan be displayed. The cursor lines can also be used to spread, i.e. magnify,certain curve sections over the full graphic width. Free scaling of the Y axisenables selecting the display size of the individual channels.
7.13.1 Setting of standard graphics
• Select screen page 45.0
Fig. 115: Screen page 45.0: Setting of standard graphics
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Operation modes of standard graphics
The operating mode depends on the key switch position.
– In key switch position "0" (key removed) standard graphics operates inthe operating mode set in line 45.04.
– In key switch position 1 to 8 a switchover to single display alwaysoccurs, independent of the operating mode set in line 45.13.
• In line 45.04, enter required operating mode:
– "0" standard graphics switched off– "1" single display: recording and display of the data is started on page
46.0 by pressing Softkey "Start single recording"; for a new recordingthe Softkey must be pressed again
– "3" cyclic measurement: The recording and display of the data occursautomatically in the rhythm set in line 45.13
• In line 45.11 enter the required measuring time, e.g. injection and dwell pressure time; the measuring time can encompass any part of a cycle or a number of cycles
• In line 45.12, enter start delay; entering "0" starts the measurement with injection start
• In line 45.13, enter an automatic measuring interval; entering "0" means every cycle is measured, entering "1" means a cycle is jumped after every measurement, entering "2" means two cycles are jumped after every measurement etc.
• In line 45.16, enter the number of actual curves (max 20), which are graphically displayed on screen page 46 from every channel. This means that after a new measured value is taken up, the graphics are not deleted but the new actual curves are drawn into the existing graphics.
• Line 45.17 "Standard graphics for unit"only multi-colour/multi-component injection moulding machines Standard graphics is active for the injection unit selected in this line. This applies up to an amendment in this line or at least for one cycle
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Scaling of the display
By entering scaling values the display size of the individual channels can beset. The maximum measuring range is limited by the maximum input signal of10 V.
• Select screen page 45.1
Fig. 116: Screen page 45.1: Scaling the display of standard graphics
• In line 45.1.03 enter scaling value for channel 1 (hydraulic actual value,max. 200 bar); to achieve a more accurate display, an entry of slightly above the expected actual injection pressure is recommended
• In line 45.1.06, enter scaling value for channel 2 (screw stroke, max. 500 mm); to achieve a more exact display, an entry of slightly above the set screw stroke is recommended
• In line 45.1.09, enter scaling value for channel 3 (mould cavity pressure, max. 3000 bar); to achieve a more exact display, an entry of slightly above the actual mould cavity pressure is recommended
• In line 45.1.12, enter scaling value for channel 4 (required injection pressure); for an exact display, the same set value as for channel 1 must be entered
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7.13.2 Display of the standard graphics
Standard graphics is displayed on screen page 46.0 according to the settingson page 45.0 and 45.1. On page 46.0 the spread of the display, i.e. magnifieddisplay of certain areas, and the exact determination of the measured valuesat various points is possible.
The exact measured values for the position of cursor 1 and cursor 2 aredisplayed left next to the display window. The cursor position can bechanged. In key switch position 1 a switchover to single display alwaysoccurs, independent of the operating mode set in line 45.04.
• Put key switch in position 1
• With Softkey "Change cursor" determine the cursor whose position should be changed; the selected cursor and its actual position appear in red under the display window
• Put cursor in the required new position with arrow keys "Right" or "Left"; the relevant measured values appear to the left of the display window
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• To spread the area between cursor 1 and cursor 2 over the whole display window, i.e. displayed enlarged, press Softkey "Spread"; multiple spreading is possible
• To cancel spreading, press Softkey "Cancel spreading"
• To again call up spreading press Softkey "Start single recording"
Enlarge display (spreading) by measurement with time acceptance
The area between cursor 1 and cursor 2 can be used for a newmeasurement; the values, set on screen page 45.0, for measurement timeand start delay are ignored during this measurement.
• Select operating mode 1 (line 45.04, value "1")
• Bring cursor 1 and cursor 2 into the required position
• Press Softkey "Measurement with time acceptance"; measurement is made and the result displayed over the whole window
• By changing to operating mode 3 or by pressing Softkey "Start single recording" the values set on page 45.0 become effective again
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7.14 Working with the background set of data
The machine is equipped with two data sets: one foreground parameter dataset, with which the machine works and a background set of data, which is notactive. Both sets of data can be identical or different. The background set canbe worked with at any time, independent of production, i.e. independent ofthe selected operation mode. It can be used to optimize the foreground set ofdata or to create a new set for planned production. Reading the backgroundset of data in and out on disk (comp. see Chapter 7.15 "Storing and readingof parameter sets") is possible.
To work on it, the screen must be switched over to the background set ofdata.
Background and foreground set of data are basically exchanged, not copied.After exchange, the original values of the foreground set remain also in thenew background set.
7.14.1 Optimizing the foreground data set in the background
• Select screen page 11
Fig. 118: Screen page 11: Working with the background data set
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• In line 11.03, enter value "1" to copy the foreground set of data into the background data set; by confirming the entry with the "ENTER" key the transmission occurs with out further enquiry; the existing background data set is overwritten
• Press key "Foreground/background data set" to display the background data set; screen colour changes to indicate that the background data set is displayed
• Work on data set; the actual values of the currently running production can be switched on or off with Softkey "Actual values on/off" on screen page 11
• For transmission of background data set into the background data setset operation mode selector switch in position "Setting"
• When the complete set is to be exchanged, close the mould
• Select screen page 11
• In line 11.06 enter "1" to exchange only the changed data between foreground and background data set (precondition: the mould number is the same), or enter "2" to exchange the foreground set of data completely with the background set of data
7.14.2 Preparing a new data set in the background
A completely new data set can be created or an existing data set can be readin from a data carrier (EEPROM or disk) in the background.
• Press key "Foreground/background data set" to display the background data set; screen colour changes to indicate that the background data set is displayed
• Work on data set; the actual values of the currently running production can be switched on or off with Softkey "Actual values on/off" on screen page 11
• For reading in of complete data sets or data blocks from a disk see see Chapter 7.15 "Storing and reading of parameter sets"
• For transmission of background data set into the background data setset operation mode selector switch in position "Setting"
• When the complete set is to be exchanged, close the mould
• Select screen page 11
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• In line 11.06 enter "1" to exchange only the changed data between foreground and background data set (precondition: the mould number is the same), or enter "2" to exchange the foreground set of data completely with the background set of data
7.14.3 Comparing foreground data set and background data set
• Select screen page 11
• In line 11.10 enter "1" to compare the data sets totally
Only the message "Data sets equal" or "Data sets not equal" appears
• For an exact comparison enter "1" in line 11.13 to compare individual elements of the data sets
Unequal values are marked in red in the background data set.
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7.15 Storing and reading of parameter sets
To shorten setting time, the complete parameter set of a fully set machinecan be read out and later read in on an EEPROM data carrier or a standard3.5" disk. Reading in can be done in the background while the machinecontinues to produce with the foreground data set (see Chapter 7.14"Working with the background set of data").
7.15.1 Formatting data carrier
Standard IQT operator terminal
ATTENTION!Before a brand new data carrier is used for saving data it must beformatted. Formatting erases existing data from disk.
For 3.5" disk drives, 3.5" DS/HD disks must be used. They are formatted toDOS format and storage capacity of 1.44 megabyte.
Procedure: • Put key switch in position 2
• Select screen page 10
Fig. 119: Screen page 10.0. Formatting data carrier
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• Select data carrier type in line 10.02
• Insert data carrier
• After selecting data carrier "Disk" type, set operation mode selector switch to position "Setting"
• Enter value 3 in line 10.06.
• Actuate key "Enter"; the question appears: "Formatting? yes=1/no=0"
• Enter value 1
• Actuate "ENTER" key; formatting begins
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IQT operator terminal type IQT.net (option)
ATTENTION!Formatting erases existing data from disk.
For 3.5" disk drives, 3,5 HD disks must be used They are formatted toDOS format and storage capacity of 1.44 MB.
Procedure: • Put key switch in position 2
• Set operation mode selector switch in position "Setting"
• Select screen page 10
Fig. 120: Screen page 10.0: Formatting data carrier
• Insert disk into drive
• Enter value 3 in line 10.06
• Actuate key "Enter"; the question appears: "Formatting? yes=1/no=0"
• Enter value 1
• Actuate "ENTER" key; formatting begins
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7.15.2 Storing data set on disk
Standard IQT operator terminal
ATTENTION! The data carrier must not be removed during the reading in or readingout process.
Data carriers can only be read out and read in in "Setting" mode.
Before a brand new data carrier is used for saving data it must beformatted (see Chapter 7.15.1 "Formatting data carrier")
Procedure • Select screen page 21.0
Fig. 121: Screen page 21.0: Enter operating data for data carrier
• For later file identification the parameter set to be stored must be labelled with the following entries (numbers or text):
– Material number in line 21.06– Mould number in line 21.08
• Select screen page 10
• Put key switch in position 2
• Enter data carrier type in line 10.02
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• Insert data carrier
• After selecting data carrier "Disk" type, set operation mode selector switch to position "Setting"
• Enter value 2 in line 10.06
NotesEEPROM data carrier can be written on in every operating mode. Duration is approximately 60 seconds
Disks can only be written on in operation mode "Setting". The disk drive is a precision engineered device; vibrations of the recording head can cause errors during recording
File numbers and date are automatically allocated when writing on data carrier
If a coded mould is used and coded plug is connected the actual value of the mould number is stored on the disk
Approximately 6.000 bytes storage space is required for one parameter set. This can increase by 8 – 9 KB if setting information becomes more comprehensive. The storage capacity of the EEPROM data carrier amounts to 32 KB, that of the 3.5" disk more than 1 MB
Disks must be removed from the disk drive when the machine is transported or operated. Vibration can cause the recording head to impact on the disk's magnetic surface or become dirty, thereby causing it to be come damaged.
IQT operator terminal type IQT.net (option)
ATTENTION!The data carrier must not be removed during the reading in or readingout process.
Data carriers can only be read out and read in in "Setting" mode.
Before a brand new data carrier is used for saving data it must beformatted (see Chapter 7.15.1 "Formatting data carrier")
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Procedure • Select screen page 21.0
• For later file identification the parameter set to be stored must be labelled with the following entries (numbers or text):
– Material number in line 21.06– Mould number in line 21.08 for non-coded moulds
• Put key switch in position 2
• Set operation mode selector switch in position "Setting"
• Insert disk into drive
• Select screen page 10
• Enter value 2 in line 10.06
• Remove disk from drive after writing process
NotesDisks can only be written on in operation mode "Setting". The disk drive is a precision engineered device; vibrations of the recording head can cause errors during recording
File numbers and date are automatically allocated when writing on data carrier
If a coded mould is used and coded plug is connected the actual value of the mould number is stored on the disk
Approximately 6.000 bytes storage space is required for one parameter set. This can increase by 8 – 9 KB if setting information becomes more comprehensive. The storage capacity of the 3.5" disk is 1.44 MB
Disks must be removed from the disk drive when the machine is transported or operated. Vibration can cause the recording head to impact on the disk's magnetic surface or become dirty, thereby causing it to be come damaged.
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7.15.3 Reading out specific data sets from data disk
Display file index of data carrier
• Set operation mode selector switch in position "Setting"
• Put key switch in position 1
• Select screen page 10
• Enter data carrier type in line 10.02
• Insert data carrier
• In line 10.06 enter "1" (file overview)
• Screen page 10.1 appears and the stored files on the selected data carrier are displayed; if the list of files is too long for one page, you can leaf through the list with softkeys "Page up" and "Page down"
Fig. 122: Screen page 10.1: File overview
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Selection of data to be read
ATTENTION!To read in and out from disks always set the operation mode selectorswitch on "Setting".
The data carrier must not be removed during the reading in or readingout process.
When reading the data into the machine the data set in the EE-PROM(machine memory) is overwritten.Tab. 3: Data type
Data typeLine 10.1.2
What is read in? Requirements
Machine dataEnter: "1"
• Mould related required values• no robot data• no core pulling data
• Operation mode selector switch in position"Setting"
• Key switch in position 1• Mould height adjustment is necessary after
reading in
Setting informationEnter: "2"
• Contents of screen pages 12.0 to 12.6• Contents of screen pages 13.0 to 13.2
• Key switch in position 1• Mould height adjustment not necessary
after reading in
Process graphics data(option)Enter: "3"
• Process graphics: two required value curves for the required and actual value adjustment and tolerance monitoring
• Key switch in position 1• Mould height adjustment not necessary
after reading in
Robot data(option)Enter: "4"
• Robot data • Robot control occurs via the IQT machine control
• Operation mode selector switch in position"Setting"
• Key switch in position 1• Mould height adjustment is necessary after
reading in
Core pulling dataEnter: "5"
• Core pulling data of the editable core puller
• Operation mode selector switch in position"Setting"
• Key switch in position 1• Mould height adjustment is necessary after
reading in
EUROMAP 17Robot data(option)Enter: "6"
• Robot data for extraction device type "Wittmann" and "Wemo"
• Robot control occurs via the IQT machine control
• Operation mode selector switch in position"Setting"
• Key switch in position 1• Mould height adjustment is necessary after
reading in
All dataEnter: "7"
• all mould related required valuesincl. Robot and core pulling data
• Robot control occurs via the IQT machine control
• Operation mode selector switch in position"Setting"
• Key switch in position 1• Mould height adjustment is necessary after
reading in
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• In line 10.1.02, enter which file type should be read out (compare Tab. 3 on page 132)
• Press Softkey "Read file" after selecting data block
• Enter number of the file to be read out; if a coded mould is used the file is only read out, when the mould number and the data set match
• Depending on the type of the data to be read, one of the messages "Read machine data", "Read robot data" or "Reading file" is displayed
• After transmission of files of type "1" (machine data), "4" (robot data), "5" (core pulling data), "6" (robot data for extraction unit type "Wittmann" and "Wemo") and "7" (all data), a jump to screen page 50 occurs, to make the necessary mould height adjustment
• Make mould height adjustment as described in "Carrying out mould height adjustment", page 10
• As a control, check values of screen pages 50 to 52
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Erasing files
• Put key switch in position 1
• Select screen page 10
• Enter data carrier type in line 10.02
• After selecting "Disk" type data carrier,set operation mode selector switch in position "Setting"
• In line 10.06 enter "1" (file overview)
• If the file overview is longer than one page, you can leaf through the list with softkeys "Page up" and "Page down"
• When the file to be erased is found, press Softkey "Erase file"
• In the dialogue field "Erase file No. ..." enter file number
• In dialogue field "Erase yes = 1 / no = 2" enter "1"; the file will now be erased
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7.16 Printing screen pages
7.16.1 Connecting printer
Screen pages can be printed with a connected printer (not part of Package).An automatic printout is possible. The printout occurs selective in mode"ASCII" (text only) or "Graphic" (text and graphic).
The printer must have a parallel interface (a serial printer interface is anoption). Usable are pure text printers (7-Bit-ASCII), printers of the productrange Epson LQ, NEC P6/ P7, Hewlett-Packard Deskjet and othercompatible printers.
• Connect printer to the printer interface at the IQT operator terminal
• Connect printer to the Schuko protective socket at the IQT operator terminal
• In line 16.2.02 enter printer type; printer type "5" (disk) does not produce a paper printout but an ASCII-file on an inserted disk (ASCII-file or bmp-file
• In line 16.2.08 to 16.2.11 select the required component parts of the IQT-screen for printout
• In line 16.2.13 enter the required number of lines per printed page; 36 lines correspond to two IQT-screen pages
• In line 16.2.14 and 16.2.15 indicate the desired upper and lower margins for the pages in empty lines
• Call up screen page 16.3 with softkey "change interface"
• Assign the interface configuration X0 to the printer (parallel printer interface)
The system printer must first be installed in the WindowsNT operating systemof the IQT.net and defined as standard printer. The system printer can beoperated from IQT.net or from a network printer server.
• In line 16.02.02 enter value 6
• In line 16.2.19 enter value 1
• Select system printer by entering corresponding code
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7.16.3 Printing individual pages
• Put key switch in position 1
• Select screen page 16
• In line 16.02, enter "1" (printing via print key) or "2" (printing via print key or automatic)
• Select required screen page
• With key "Switchover print mode ASCII / graphic" select ASCII or graphic print
• Actuate "PRINT" key
7.16.4 Automatic printout
• Put key switch in position 1
• Select screen page 16
• In line 16.02 enter value "2" (print via print key or automatic)
The page numbers of the maximum five pages to be printed can be selecteddirectly or composed in the select mode.
Entering page numbers directly
• In line 16.07 to 16.11, enter the screen pages to be printed automatically
• In line 16.12, indicate if the messages are to be printed with the printout
Selecting pages in select-mode
• Press Softkey "Select page" to switch the select-mode over; page 16 is faded reduced into the screen
• Select the required page and press "ENTER" key; the page number appears in line 16.07 of the faded-in window
• Select further pages in the same way; if more than five pages are selected, the cursor jumps back to line 16.07 and overwrites the previous selection
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• When all pages have been selected, press key "CLEAR" to end the select-mode
• In line 16.12, indicate if the messages are to be printed with the printout
Fig. 126: Screen page in select-mode with page 16 faded in
Enter print interval for automatic print
• In line 16.14, enter time interval for automatic printout; the interval begins with the input, input of a time interval of "0.00" switches off the time controlled automatic printout
• In line 16.15, enter time interval for the automatic printout; the interval starts with the machine cycle at the time of entry, entering a cycle interval of "0" switches off the cycle controlled automatic printout
• In line 16.16, indicate if the printout should also occur at automatic machine shut-down
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7.17 Preparing for operation
ATTENTION!Make a check of the safety devices at the start of every shift. At eachcheck the machine must effectively shut off. The checks must be madein the sequence set out.
Never work with the machine if a safety device fails during a test. Havethe safety device set in working order without delay.
Observe all safety instructions
7.17.1 Prerequisite
Before starting production the following conditions must exist:
• The machine is fully set up
• The required parameter set is loaded
• Machine-relevant data have been checked
• Production-relevant data have been checked
7.17.2 Short inspection before start of work
Before switching on the machine you must make a short inspection of themachine and its surroundings.
ATTENTION!Before starting your shift inspect the machine for any visible externaldamage, such as, leakages on the hydraulic equipment, loose cableconnections and mechanical damage.
Have any damage or faults repaired by qualified personnel, before youoperate the machine; this applies especially to damages of safety devicesand hydraulic equipment.
• Loose cable connections and noticeable mechanical damage?
• checked oil level in oil level viewing glass?
• Removed obstacles in machine area; machine freely accessible from all sides?
• Reaching into mould blocked from all sides? (visual check - reaching in from underneath and check peripheral equipment)
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• Are limit switches on safety devices functioning?
• Contact bank on safety gate functioning properly?
• Limit stops and guides of safety door functioning properly?
• Heating adjusted to the material being processed?
• Setup key removed?
• Is discharge chute secured against reaching in?
• Squash and cutting places on plasticizing unit secured?
• Injection moulding machine free from oil- and water leakages?
• Work place free from causes for tripping, granules and other contaminants?
WARNING!Remove oil spots from the machine immediately and thoroughly!
Dispose of oil soaked rags and oil containers immediately and properly!
• if necessary remove oil spots on the floor around the machine
• if necessary remove spilled plastic granules from the floor
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7.17.3 Fill hopper
ATTENTION!Do not climb onto the machine to fill the hopper with raw material.Always use safe ladders or steps. For heavy bulk loads a suitable liftingdevice must be used.
DANGER!Individual machine parts can be very hot. Never support yourself onany part of the machine!
• The hopper must be filled with the appropriate raw material
Fig. 127: Material hopper, example
1 Hopper, resin.2 Guide plate3 Heater band
For removal of material no longer required, the guide plate is fitted with andischarge position
1
2
3
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Fig. 128: Hopper operating elements
1 Pin, locking2 Locking lever3 Material feed injection unit4 Pivot bearing5 Guide plate with discharge port
Emptying hopper The guide plate has an opening for emptying the hopper. The hopper ismoved over this guide plate
NoteBefore sliding the hopper over the discharge opening set up a collecting vessel. The material will flow immediately from the hopper!
Sliding the hopper • Lift locating plunger and move hopper into desired position
• Re-insert plunger
Swivelling the hopper • Move hopper into its rest position over the pivot bearing
• Loosen locking lever and swivel out guide plate with hopper into the position required
• After swivelling in tighten locking lever
5 1
4
2
3
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7.17.4 Switching on cooling water supply
Open valve
NoteCooling water lines and auxiliary cooling devices are to be installed by user.
• Setting up cooling water system installed by user
Checking flow regulator setting
The cooling water flow rate is controlled manually via the correspondingcircuit of the cooling water manifold. A central swimmer position in theviewing glass is recommended. This ensures a turbulent flow and thereby theleast amount of deposit in the cooling channels.
Fig. 129: Cooling water manifold
1 Specified level2 Floating cone3 Thermometer4 Return flow control valve5 Forward flow control valve
Depending on the type of mould and materials used the specified levels areto be set on the corresponding position and the rates of flow set. Dependingon the cooling water system the flow can be controlled either via supply orreturn.
1
2
3
4
5
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When carbonates and phosphates etc. are present, water which is notadequately treated and a flow rate which has been set too low increases boththe rate of deposit and the follow-up temperature. This does not present aproblem in factory-wide closed cooling water circuits; neither is the re-coolingcapacity increased since heat dissipation remains constant.
Higher flow rates also do not present a problem, as long as the increasedflow rates are supplied by the factory cooling system.
Further information: see Chapter 5.4.4 "Cooling water connection"
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7.17.5 Switching on machine
Selecting setting mode
Before beginning automatic operation various units must be switched on.This is done in setting mode.
• Set operation mode selector switch in position "Setting"
Fig. 130: Operation mode selector switch
Further information: see Chapter 4.5.3 "Key board switch"
Switch on main switch
Fig. 131: Main switch on electric cabinet
1 Position on2 Position off
• Turn on main switch (see Fig. 131; Pos. 1)
The control is powered up. After expiry of the initializing phase the machine is operational; screen page 0 "List of contents" appears at the IQT
1
2
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Fig. 132: Screen page 0: List of contents
Check for messages
During the initializing phase the control checks the state of various systems.Should a fault be detected, corresponding messages are displayed in thealarm overview.
Fig. 133: Key for alarm overview
• Press key "Alarm overview" to call up current messages
Message "Mains voltage failed"
Since mains power was just turned on, the message "Mains voltage failed"appears
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Fig. 134: Key to erase the message
• Press key "ERASE" to erase message "Mains voltage failed"
ATTENTION!Do not erase all other messages until cause of fault has been removed.
Switching on pump motor and cylinder heating
Fig. 135: Keys "Pump motor on" and "cylinder heating on"
• Actuate key "Pump motor on"
The hydraulic system starts up. The hydraulic system is put under working pressure
• Actuate key "Cylinder heating on"
The screw cylinder is heated to the parameters set
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Actuate safety gates
• For the sake of the safety circuits the front and rear safety gates must be opened and closed
A message must appear (see Chapter 6.3.2 "Checking movable safety gates").
Fig. 136: Start key
• Actuate key "Start" to erase the message
7.17.6 Setting oil preheating
The oil preheating provides for flawless and wear reducing machineoperation and prevents damage. Oil preheating can be started by theoperator after the machine is switched on; however, it is recommended tostart the oil preheating automatically after every machine start. When oilpreheating is switched on and the set oil temperature is not reached allmachine movement is blocked.
To start oil preheating automatically
• Set operation mode selector switch in position "Setting"
• Switch off motor
• Select screen page 15
• Enter the preheat temperature (max. 35 °C) in line 15.05
• In line 15.03 enter "1" to switch on automatic oil preheating
• Switch on motor
The message "Oil preheating running" appears. All machine movements are blocked until the set preheating temperature (max. 35 °C) is reached
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To start a machine cycle the oil preheating temperature must have beenreached or value 0 must be entered in line 15.03.
The actual oil temperature is displayed in the status display (Pos. 5) on thescreen.
If value 0 is entered in line15.03, oil preheating is activated after each start ofthe machine with main switch ON and switching on the motor.
If oil preheating should be activated after a pause in production (without mainswitch OFF) the following procedure is necessary:
• Set operation mode selector switch in position "Setting"
• Enter the preheating temperature (max. 35°C) in line 15.05
• Enter value 0 in line 15.03
• Enter value 1 in line 15.03
• Switch on motor
Fig. 137: Screen page 15: Oil preheating: switch on and required value
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7.17.7 Activating central lubrication (option)
Central lubrication provides lubrication for:
– the rod guides in the moving mould clamping platen
The lubrication interval is determined via the IQT operator terminal.
Line 15.07, value 0 Central lubrication is switched off
Line 15.07, value e.g. 500 After every 500 machine cycles a lubricating interval starts. The intervalshould be selected so that there is always a thin grease film present.
Function Each time the number of cycles entered in line 15.07 has run down, and afterclamping pressure release, a lubricating cycle starts. The grease pump thenpresses grease into the lubricating points via the distributors. Limit switcheson the distributors monitor if the grease has flowed through all lines. If thissignal is not received after a fixed monitoring time, the message "Lubricatingpressure not reached" is displayed. Also, the message "Lubrication, reservoirempty" is displayed when the grease reservoir is empty.
NoteWhen central lubrication is activated in line 15.07, a lubricating interval starts each time the motors are switched on.
Topping up the grease reservoir.
Use the recommended lubricants for topping up the reservoir see Chapter10.3 "Lubricant recommendations"
7.17.8 Checking by-pass oil filtration and oil cooling
A separate pump unit is installed in the hydraulic system for by-pass oilfiltration and oil cooling. This circuit is activated by pressing key "Pump motoron".
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7.18 Starting production
7.18.1 Reaching processing temperature
• Wait an additional 15 minutes after screw release, until theplasticizing cylinder has reached the set operating temperature
• If the user operates mould heating, wait until the specified processing temperature is reached (see Chapter 7.5 "Smould heating (option)")
7.18.2 Plasticizing in manual mode and purging screw cylinder
To have excellent material for injection, plasticize several times withmaximum plasticizing stroke to purge the screw cylinder.
Fig. 138: Operation mode selector switch
• Put operating mode selector switch in position "Manual"
Fig. 139: Machine relevant key board
1 Injection unit return2 Plasticizing3 Injection
• Actuate key "Injection unit return" and move injection unit to its rear position
1
23
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Fig. 140: Screen page 40.0: Injection unit: Plasticizing, cooling time
• Select screen page 40.0
• Enter maximum plasticizing stroke in line 40.02
• Switch on screw suck-back before plasticizing, to do this enter
– 20 mm screw suck-back stroke in line 49.09 and– 5 mm/s screw suck-back speed in line 49.10
• Actuate key "Injection"
After releasing the key "Injection" the plasticizing process starts automatically.
• Purge screw cylinder. To do this keep key "Injection" pressed until the screw has reached its forward position
7.18.3 Position screw for production
• Select screen page 40.0
• Enter plasticizing stroke for production in line 40.02
• Enter screw suck-back parameters for production
• To move the screw into position, again purge screw cylinder in manual mode
After releasing key "Injection" a new plasticizing process begins until the set plasticizing stroke is reached.
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7.18.4 Running a test cycle
Select operating mode "Manual"
• Put operating mode selector switch in position "Manual"
Open mould
• Press key "Open mould" and move mould to opening width (according to specified parameter)
• Put operation mode selector switch in position "semi-automatic"
• Actuate "Start" key
The machine runs one cycle and then stops
• Check moulded part
• If it is faultless and no other adjustments are necessary, automatic operation can commence.
Selecting operating mode "Automatic"
• Put operation mode selector switch in position "Automatic"
• Actuate "Start" key
ATTENTION!When a fault occurs remove its cause or have it removed by a qualifiedperson before operating the machine again.
Watch for unusual machine movement or noises during automaticoperation.
12
3
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7.18.5 Parameter set for production start (option)
After start of production, during a settable number of machine cycles, variousrequired values are replaced by certain starting values. These starting valuesare summarized on screen page 40.2, in the parameter set for productionstart.
• Select screen page 40.0
• Actuate Softkey "start cycles", to call up screen page 40.2
• The number of start cycles can be entered for the injection process (line 40.2.02) as well as for mould safety (line 40.2.17)
The following is considered as production start:
• change from operation mode "setting" or "manual" to operation mode "semi-automatic" or "automatic"
When the above-mentioned operation has been executed and the startprogramme is switched on, the start cycles begin. The messages "productionstart: parameter active" and "production start: mould safety active" aredisplayed.
The start program is switched off or can be switched off when value 0 isentered in lines 40.2.02 and 40.2.17.
Fig. 142: Screen page 40.2: Parameter set for production start
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7.19 Material or colour change
During material or colour change all the old material or colour must be purgedand the hopper filled with new material. Sometimes it is advisable to purgethe old material at a temperature which lies in the lower range of themanufacturers recommended temperature. This increases the friction of thematerial in the screw cylinder and improves the cleaning results.
ATTENTION!Each material makes certain demands regarding its processingtemperatures. Observe the manufacturers recommendations.
If the old material is temperature sensitive and the new material requires hightemperatures, use a material in the intermediate stage which is nottemperature sensitive until all the old material has been completely purgedfrom the screw cylinder. Following that, the material used in the intermediatestage can be purged from the screw cylinder and replaced by the newmaterial. Polyethylene, polypropylene, and polystyrene are useful asintermediate materials.
When changing from a high temperature to a lower temperature material,clean out the cylinder at low temperature. Use an intermediate material ifnecessary.
DANGER!You must wear protective clothing, safety glasses and face shield.Pressurized gas could be expelled from the screw cylinder and couldcause serious personal injuries.
Colour change can be made with the same or similar material as follows:
• Purge the old colour at low temperature
• Switch off motor
• Thoroughly clean hopper and feed zone
• Material remains in the hopper, especially fine material dust, can lead to delayed colour change
• Fill hopper with the new material
• Purge screw cylinder at low temperature until all material is purged completely from hopper
• Start new injection cycle
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7.20 Work breaks
• During short work breaks press key "Pump motor off" to switch off the machine
• During longer work breaks press key "Reduce cylinder temperature", and with heated moulds press key "Reduce mould temperature"
• To resume production press key "Cylinder heating on" to reheat the screw cylinder
• When using mould heating press key "Mould heating on" to reheat the mould
• Wait for screw release and mould release and then resume production
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7.21 Switching machine off
DANGER!You must wear protective clothing, safety glasses and face shield.Pressurized gas could be expelled from the screw cylinder and couldcause serious personal injuries.
Before switching the machine off, before maintenance work and beforeremoval of the screw cylinder the screw cylinder must be purged.
7.21.1 Emptying hopper
DANGER!Individual machine parts can be very hot. Never support yourself onany part of the machine!
The hopper must be emptied accordingly, see Chapter 7.17.3 "Fill hopper".
7.21.2 Purging screw cylinder
• If necessary fill with cleaning granules and flush screw cylinder
• The screw cylinder must be purged accordingly (see Chapter 7.18.2 "Plasticizing in manual mode and purging screw cylinder".)
• For safety reasons, again enter the plasticizing stroke for production in line 40.02 on screen page 40.0
7.21.3 Moving screw into forward position
Fig. 143: Machine relevant key board
1 Pump motor off2 Cylinder heating off3 Injection
2
3
1
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• Press key "Injection" and keep it pressed
• Set operation mode selector switch in position "Setting"
• Release key "Injection"
Fig. 144: Operation mode selector switch
7.21.4 Switch off cylinder heating
• Press key "Cylinder heating off"
7.21.5 Switching off hydraulic unit
NoteIn case of monosandwich injection moulding machines with vertical injection unit the horizontal unit must be moved to its rear position before the pump motor is switched off. This prevents the vertical unit from sitting on the horizontal unit in case the vertical unit is lowered.
• Actuate key "Pump motor off"
7.21.6 Allow screw cylinder to cool
ATTENTION!To allow controlled cooling of the screw cylinder without endingfeedthroat cooling, wait before switching off the main switch and thecooling water supply.
7.21.7 Switching off main switch
• Set main switch on electric cabinet on "Off"
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7.21.8 Shutting off cooling water supply
NoteCooling water lines and auxiliary cooling devices are to be installed by user.
• Shut off user-installed cooling water supply
7.21.9 Shutting down the machine immediately in an emergency with the emergency-off function and restarting
The emergency-off function is triggered by actuating the emergency-offbutton. It effects:
• Immediate cycle interruption
• Shutdown of all machine movement
• Shutdown of motor
• Shutdown of heating (screw cylinder and mould)
Fig. 145: Emergency-off switch
To continue machine operation:
• Disengage "Emergency-off key"
• Actuate "Start" key
• Switch on motor
• Switch on heating
• Open and close front safety gate
• Actuate "Start" key
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7.22 Weekday timer (option)
The day timer is an option and is available as follows:
• Channels for motor and heating
• One additional external channel
• Two additional external channels
The external channels are made available either via relay or contactor(customer's choice) and socket.
One turn-on and one turn-off time can be programmed per weekday which isthe same for all channels (lines 14.09 to 14.15)
When using a weekday timer it is important that date and time are accuratelyset (see screen page 19). Important for the weekday timer are the machinecalendar and clock.
Line 14.02 Entering 1 activates the weekday timer. Entering 0 switches it off.
Line 14.03 Here the date for the start of timer activity is entered.
Lines 14.04and 14.05
By entering 1 the channel becomes active. Entering 0 switches the motor orthe heating off.
The manual keys for motor and heating and the timer channels operate inparallel. This means that when the channel is switched off the switchingstatus of motor and heating is determined by the manual keys. The requiredstatus can be restored by the manual keys even when channels are switchedon. The timer continues operating independently.
Line 14.06and 14.07
There are three selections:
– Value 0: the channel is permanently off– Value 1: the channel operates with the times programmed set on the
day timer– Value 2: the channel is permanently on
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Lines 14.16to 14.19
By means of a switch-on and a switch-off delay time per channel individualswitch-on and switch-off times per channel can be achieved.
Setting • Switch on the timer (line 14.02, value 1).
• In line 14.03 enter the date from which the timer is to be switched on, e.g. at an extended standstill of the machine.
• Enter the switching time times for the corresponding day of the week (lines 14.09 to 14.15).
• Enter the delay times for switch-on and switch-off for the corresponding channels (lines 14.16 to 14.19).
• Determine the status for the individual channels (lines 14.04 to 14.07)
• Check date and time on screen page 19 and reset them if necessary.
NotesIf value 0.00 is entered for a switching time, the respective switch-on/off time is ignored.
In connection with the temperature reduction (line 30.19), the heating is not entirely switched off via the timer but the temperatures are lowered to the entered value.
The switch-off times for motor and heating are taken into account also in operating modes Setting and Manual; message: "Timer run down".
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7.23 Process graphics (option)
Process graphic (screen pages 45.0 to 47.1) is offered as an option. On agraphic overview (page 46.0) 4 parameters can be displayed simultaneously:
Channel 1: Specific injection pressure, actual value
Channel 2: Screw stroke
Channel 3: Mould cavity pressure
Channel 4: Hydraulic pressure, required value
Fig. 146: Screen page 46.0: Process graphics overview
The duration of the registration can be selected freely. This allows the wholeinjection process to be displayed and monitored according to presetmeasuring time.
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Cursor lines, spreading Two cursor lines permit the measurement of all plotted curves. The maximumvalues of each curve as well as the curve values corresponding to eachposition of both cursor lines are displayed aside from the graphics. Inaddition, through appropriate selection of marginal conditions curve sectionscan be enlarged, i.e. a curve section can be isolated with both cursor linesand then spread over the entire width of the graphics. Multiple spreading ispossible. This magnifying effect allows precise examination of individualcurve sections. Furthermore, by entering the scale end values for the Y-axisthe display size of the individual channels can be freely selected.
Required and actual value comparison
By means of process graphics a required and actual value comparison(screen pages 46.1 and 46.3) and tolerance monitoring (screen pages 46.2and 46.4) can be carried out in the single display of the measured values. Forthe required and actual value comparison, a specified required curve (storedactual curve with ideal curve trace) is overwritten by an actual curve afterevery machine cycle. Required and actual curves have different colours sothat deviations can be easily recognized.
Fig. 147: Screen page 46.1: Process graphics required and actual value comparison 1
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Tolerance monitoring For tolerance monitoring the stored reference curve can be occupied by atolerance field which can be freely selected. Then, the actual curve trace isrecorded into this tolerance band cycle by cycle.
Fig. 148: Screen page 46.2: Process graphics tolerance monitoring 1
Injection work The graphics system also offers the option of calculating the injection work(screen pages 47.0 to 47.1). The injection work is a characteristic size whichlinks the most important parameters of the injection process. In connectionwith the calculation of the injection work, injection speed and injectionpressure in dependence of screw stroke are graphically displayed on screenpage 47.1.
Fig. 149: Screen page 47.1: Process graphics injection work speed
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7.23.1 Setting process graphics
Process graphics is set on screen pages 45.0, 45.1 and 47.0.
Line 45.17: Process graphics for unit
Process graphics is active for the injection unit selected in this line. Thisapplies up to an amendment in this line or at least for one cycle
Line 45.04: Maximum stroke for x-axis operation modes
In connection with key switch position 0, process graphics remains in themode selected on screen page 45.0.
When changing key position into a position greater than 0, process graphicschanges from preselected operating mode 3 (cyclic measurement) intooperating mode 1 "Single diagram without monitoring". When operating mode 1 "Single diagram without monitoring" or operatingmode 2 "Single diagram with monitoring" is pre-selected and key switchposition is changed to a position greater than 0, operating mode of processgraphics does not change. The selected and currently active operating mode is displayed in each displaypage (screen page 46.0, 46.1, 46.2, 46.3, 46.4 and 47.1). Recording startswith signal "Start injection".
Operating mode 1
Single diagram without monitoring
A single recording is made which is requested by actuating softkey "Startsingle recording" and then remains on screen for evaluation. Required andactual value comparison and tolerance monitoring are now active for only onerecorded measuring process. However, process monitoring does not takeplace. In this operating mode all options for operating process graphics, suchas cursor control and spreading, are available.
Operating mode 2
Single diagram with monitoring
A single recording is made which is requested by actuating softkey "Startsingle recording" and then remains on screen for evaluation. Processmonitoring takes place in this operating mode. This means: During evaluationof the recorded measuring process the measurement with monitoringcontinue to run in the background for the following cycles.
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Operating mode 3
Cyclic monitoring With input of the automatic measuring interval in line 45.13 the automaticrecording of parameters cycle by cycle (line 45.13, value 0) or periodicaccording to the number of cycles pre-selected in line 45.13 takes place.
Prerequisite • Operating mode "Cyclic measurement" (line 45.04, value 3)
• Key switch in position 0
Line 45.11:Measuring time
The measuring time determines the duration of recording. Recording startswith signal "Start injection". To display the injection process the total injectiontime can be selected as guide value.
Injection times of the injection stages used are marked by short, red linesbelow the x-axis. During measuring time the message "Recordingmeasurement" appears in yellow on screen pages 46.0 to 47.1.
Line 45.12: Start delay If a value different to 0 is entered in line 45.12, recording starts after expiry ofthe delay time.
Corresponding to the input in line 45.12 recording does not start at t=0, but bythe t-value corresponding to the start delay time.
The start delay time can, e. g. be used to fade out undesired curve traces atthe start of the measuring cycle.
Line 45.13: Automatic measuring interval
The value entered in line 45.13 corresponds to the number of cycles whichwere not measured and displayed between two recordings.
Line 45.14: Maximum stroke for x-axis
The input is required for the graphics display on screen page 47.1. On screenpage 47.1 two curves above the screw stroke are traced:
• Injection pressure above screw stroke
• Screw speed above screw stroke
From the display of the specific injection pressure above the screw stroke theinjection work is calculated. The plasticizing stroke can serve as guide valuefor the maximum stroke of the x-axis.
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Display size of the individual channels
Scale end values By entering the scaled end values for the y-axis (lines 45.1.03, 45.1.06,45.1.09 and 45.1.12) the display size of the individual channels can be freelyselected. The scaled end values must not exceed the correspondingadmissible maximum value (lines 45.1.02, 45.1.05, 45.1.08 and 45.1.11). Themaximum measuring range is determined by the maximum input signal of10 V of the corresponding measured value.
Fig. 150: Screen page 45.1: Process graphics standard graphics setting 2
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Cursor control
Two cursor lines, freely movable in x-direction, are available for analyticalobservation of the processes. The actual values at the intersections of thecurved cursor lines are displayed next to the axis in the correspondingcolours. The corresponding cursor line positions are displayed below the x-axis.
Selection of cursor lines 1 and 2
• Put key switch in position 1
• Actuate softkey "Change cursor", the position display of the selected cursor line is marked in colour.
• By actuating the "Right" or "Left arrow keys the selected cursor line runs step by step to the right or left.
• The selected cursor line runs continuously to the right (left) when the arrow key "Right" (left) is continuously pressed.
Remarks: At the initial position the cursor line 1 is on the y-axis, cursor line 2 representsthe right edge of the graphics.
Magnifying effect – spreading of a curve section
To facilitate an exact examination of important sections of the process, thesection which is bordered by the two cursor lines, can be spread over thewhole display area.
• Put key switch in position 1
• Enclose curve section which is to be spread, with cursor lines 1 and 2.
• Actuate softkey "Spreading"
Remarks: Multiple spreading is possible.
When changing into operating mode 2 or 3 or when requesting a messagevia softkey "Start single recording" the times entered on screen page 45.0become effective again. The non-spread display appears.
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Measurement request with time takeover
A further possibility for spreading is offered by the working mode"Measurement request with time takeover". In this case, the time whichcorresponds to the position of cursor line 1 is taken over as start delay andthe time period between both cursor lines, rounded off to full seconds, asmeasuring time.
• Select operating mode 1 (line 45.04, value 1)
• Enclose curve section with cursor lines 1 and 2
• Actuate softkey "Measurement with time takeover"
A measurement with the newly defined start delay and newly definedmeasuring time takes place. When changing into operating mode 2 or 3 orwhen requesting a message via softkey "Start single recording" the timesentered on screen page 45.0 become effective again.
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7.23.2 Required and actual comparison and tolerance monitoring
Required and actual value comparison
The choice for which channel the required and actual comparison andtolerance monitoring should be carried out, is to be made in line 45.1.15 forrequired and actual value comparison 1 (screen page 46.1) and tolerancemonitoring 1 (screen page 46.2), and in line 45.1.17 for required and actualvalue comparison 2 (screen page 46.3) and tolerance monitoring 2 (screenpage 46.4).
Procedure: • Put key switch in position 1
• Enter the number of the channel in line 45.1.15 or 45.1.17 for which required value and actual value comparison and tolerance monitoring is to be carried out.
• Select screen page 46.1 or 46.3
• Actuate softkey "Store actual curve"
This way the last measured actual value curves of the selected channels aretaken over as reference curves. Reference curves and their correspondingvalues are displayed in green.
• Put key switch in position 0
After a new measurement request, the stored reference curves areoverwritten by the measured actual curves. The actual curves are displayedin colour harmony with the graphics overview. (screen page 46.0).
Tolerance monitoring Based on the reference curves determined for required and actual valuecomparison 1 and 2 and tolerance inputs in lines 45.1.16 and 45.1.18, thetolerance bands for tolerance monitoring 1 and 2 are installed on screenpages 46.2 and 46.4. The input for tolerance is entered in % of maximumvalue of the corresponding channel, e.g. at a maximum value of 1000 bar formould cavity pressure a tolerance of 3 % corresponds to a +/- tolerance of 30bar.
To obtain practical tolerance monitoring the measuring period (line 45.11)must have elapsed after the injection process has ended.
After a new request for measurement the measured actual curve is tracedinto the constructed tolerance band. Tolerance deviations are indicated in thefault text "Graphic: Tolerance band exceeded". The message can be erasedby pressing the "CLEAR" key.
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In operating modes "Single diagram with monitoring" (line 45.04, value 2) and"Cyclic measurement" (line 45.04, value 3), tolerance monitoring 1 and 2 canbe used for process monitoring and the control of rejects. This is done byentering permissible tolerance deviations in line 80.06.
A common deviations counter is available for tolerance monitoring 1 andtolerance monitoring 2. Counting starts when tolerance bands are exceeded.
Prerequisite: • Key switch in position 0
• Value 2 or 3 must be entered in line 45.04
• The number of permissible tolerance deviations must be entered in line 80.06
Counting process • When leaving the tolerance bands the count increases
• If the curves lie within the tolerance band the count is decreased
• The limits, minimum = 0 and maximum = value in line 80.06, are not be exceeded
• Entering value 0 or 1 in line 45.04 resets the deviations counter
After reaching the permissible tolerance deviations the machine stops onstep 62. The message "Product outside tolerance" appears. The message iserased by pressing the "Start" key.
When leaving the tolerance bands the message "Tolerance band exceeded"appears and can be erased by pressing the "CLEAR" key.
Simultaneously an electric signal is sent "Outside" which can be used forsorting rejects.
The input of value 0 in line 80.06 cancels the counting process (deviationscounter); tolerance deviations are issued via messages, however, themachine is not stopped.
NotesWhen writing on data carrier, the two required value curves defined for required and actual value comparison 1 and 2 and for tolerance monitoring 1 and 2 are stored on the data carrier.
Process graphics with all its possibilities can be operated during printout of one of the screen pages 46.0 to 46.4 and 47.1.
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Reading process graphics data from data carrier
When reading process graphics data the two required value curves from theselected file are taken over as reference curves for required and actual valuecomparison 1 and 2.
Process graphics data can be read in every operating mode of the machine.Selection of data to be read is made in line 10.1.02.
Procedure
ATTENTION!The data carrier must not be removed during the reading in or readingout process.
• Put key switch in position 1
• Select data carrier type in line 10.02
• Insert data carrier
• Enter value 1 in line 10.06. Screen page 10.1 "File overview" appears
• Enter value 3 in line 10.1.02 (reading process graphics data)
• Actuate Softkey "Read file"
• Enter file number
• Actuate key "Enter"
NoteThe required value for setting process graphics is read out together with the machine data (line 10.1.02, value 1). This reinitializes process graphics, i.e. the reference curves are erased.
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7.23.3 Calculating injection work
Calculation of injection work is integrated in the graphics system. Theprocess size indicates the work required in order to fill a certain section of themould. For instance, a change in the flow behaviour of the plastic materialleads to increased or decreased injection work. By means of a test series, thequality characteristics of the moulded parts and the injection work must bedetermined for every mould. By determining a permissible tolerance theinjection work can be used for the control of rejects.
Setting the calculation of injection work
Setting • Enter the maximum stroke for the x-axis in line 45.14. The value entered should be somewhat greater than the plasticizing stroke (line 40.02).
• Enter scaling value for speed in line 45.15
• Enter value 1 or 2 in line 47.03
• Enter the constraints for calculating the injection work in line 47.08 and 47.09. Start and end point are indicated on screen page 47.1 by cursor lines 1 and 2.
• Enter permissible tolerance (in % of maximum value) in line 47.15
Fig. 151: Screen page 47.0 process graphics: Setting for injection work
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• Put key switch in position 0
• The injection work calculated is displayed.
– In Nm on screen page 47.0– In Nm on every display page of process graphics next to the y-axis– In Nm in the trend display (line 81.2.07), see Chapter 7.9.1 "Trend
diagram"
Determination of start and end point for calculation of injection work by means of cursor lines 1 and 2
• Put key switch in position 1
• Select screen page 47.1
• Set cursor lines 1 and 2 on desired start and end point
• Actuate softkey "Work calculation between cursor lines"
The stroke values corresponding to cursor lines 1 and 2 are now taken overon screen page 47.0 as new required values for start point and end point (line47.08 and 47.09).
Fig. 152: Screen page 47.1: Process graphics injection work speed
NoteScrew acceleration and dwell pressure phase should be faded out of the injection work calculation by means of suitable selection of constraints.
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Calculation of injection work with monitoring
Line 47.03, value 2 By entering value 2 in line 47.03 the injection work can be used for processmonitoring and the control of rejects.
Prerequisite: • Process graphics in operating mode 2 or 3 (line 45.04, value 2 or 3)
• Key switch in position 0
• Value 2 must have been entered in line 47.03
• The number of permissible tolerance deviations must have been entered in line 80.06
The injection work curve displayed in the trend display on one of the screenpages between 82.0 to 86.0 is monitored The deviations counter is availablefor tolerance monitoring of the injection work. When the tolerance band isexceeded counting begins and the message "Injection work outsidetolerance" appears. The message is erased by pressing the "CLEAR" key.
• When the injection work calculated lies outside the tolerance band the count increases
• When the injection work calculated lies inside the tolerance band the count decreases
• The limits, minimum = 0 and maximum = value in line 80.06, are not be exceeded
• Entering value 0 or 1 in line 47.03 resets the deviations counter
After reaching the permissible tolerance deviations the machine stops onstep 62. The message "Product outside tolerance" appears. The message iserased by pressing the "Start" key.
The input of value 0 in line 80.06 cancels the counting process (deviationscounter); tolerance deviations are issued via messages but the machine isnot stopped.
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7.24 Statistical process control (option)
General
Statistical process control (SPC) offers the option using economical andstatistical methods to collect process data, to process and interpret themsuch that quality and productivity can be increased.
SPC basically has the function
• of clarifying whether the process is under statistical control and signalling the presence of systematic influences so that corrective measures can be taken.
• of maintaining the state "Under statistical control"
• of establishing measures for improving processing capability
Deviation, chance influences and systematic influences
A process value naturally shows certain behaviour toward deviation, alsocalled variation. This variation results from the interaction of variousinfluences. One distinguishes between systematic influences and chanceinfluences.
Systematic influences Systematic influences are based on factors which are often irregular andunstable and therefore not predicted. Moulded part quality for example canbe affected by the machine, mould, material, personnel, maintenance andwork environment.
UNDER CONTROL(VARIATION BY CHANCEINFLUENCES PARTLY REDUCED)
UNDER CONTROL
(SYSTEMATIC INFLUENCES EXIST)OUT OF CONTROL
TIME
MASS
(SYSTEMATIC INFLUENCES ARE ELIMINATED)
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Chance influences Chance influences on the other hand can be based on many factors and aretherefore present in all processes to varying degrees. If variation is caused bychance influences it results in a variation pattern which over time becomesstable and predictable and therefore provides the basis for subsequentprocess improvement.
Sample tests To measure variation behaviour, sample tests of certain size are taken atmeasured time intervals and evaluated. These results can be used formaking a prediction about the process as whole.
State: "Process under statistical control"
Via SPC the systematic causes of variation can be gradually eliminated. It issaid: The process is subjected to statistical control, i. e. the only causes forvariation are chance influences. As long as the process stays under statisticalcontrol it remains predictable with regard to consistent quality, productivityand cost.
Fig. 153: Screen page 93: SPC capability analysis
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7.24.1 Setting the SPC control charts
Before the start of automatic recording via softkey "Automatic mode" thefollowing procedure is required for proper functioning of the SPC:
• Select characteristics
• Determine size of sample, number of samples for pre-test test and number of pause cycles.
• Start pre-test
• After the completion of pre-test, set the scale of the xq/R- and xq/s charts for each characteristic.
Selection of characteristics (lines 90.02 and 90.03)
For SPC a maximum of 5 characteristics (characteristics index 0 to 4) can beselected and monitored simultaneously. For each defined characteristic theSPC charts must be set separately. Additionally, for each definedcharacteristic a capability analysis and the check for normal distribution(probability line) is carried out. Switchover between characteristics occurs viasoftkey "Next characteristic".
A characteristic is a process size for which an actual value (e.g. injectionparameter) is recorded. The selection of process size should be concentratedon those which influence part quality. This includes e.g. cushion, mouldtemperature, mass temperature, injection work, and switchover pressure.
Procedure: • Put key switch in position 1 or 2
• Select screen page 90
• In line 90.02 enter characteristics index (0 to 4)
• Select line 90.03
• Actuate softkey "enter actual value"
Now screen page 90 is displayed in reduced size and you are now in socalled select-mode.
• Call up relevant screen page on which the required actual value is found and select the required actual value via cursor keys
• Actuate key "Enter"
Now the selected actual value is allocated to the correspondingcharacteristics index.
• Select a further actual value or end selection mode by actuating key "CLEAR".
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Fig. 154: Screen page 90: Setting SPC control charts
Size of sample test(Line 90.06)
An appropriate sample test influences the effectiveness of the SPC controlcharts. The test samples should be selected so that variations between partswithin a sample test are small.
For a pre-test, sample tests can be typically made up from 5 (but at least 2)parts produced in succession.
The size of the sample test must remain "constant" for all test samples.Changing the size of the sample test during monitoring distorts the result;especially the determination of the capability index is no longer soundlybased. The size of the sample test entered in line 90.06 is the valid criterionfor the pre-test and for automatic recording.
Number of sample tests for the pre-test(Line 90.07)
From the view of the process enough pre-tests tests must be made to ensurethat all potential causes for variation have occurred. From a statistical view,20 pre-tests which contain 100 or more individual values result in a goodstability test. 20 pretests are a recommended minimum.
Example: Size of sample test = 5
The number of sample tests for the pre-test = 20
This results in 5 x 20 = 100 recorded individual values for the pre-test.
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Number of pause cycles (line 90.08)
The aim is to determine changes in the process over a period of time. For thisreason sample tests should be taken often. During one of the first processstudies sample tests are taken at short intervals (small number of pausecycles) in order to determine if the process shifts or shows other signs ofinstability over a short period. If the stability of the process increases the timeinterval between sample tests can be extended (large number of pausecycles).
• The number of the pause cycles is only taken into account in automatic mode.
• The actual values are continuously recorded during the pre-test.
• It is possible to carry out a manual sample test during a pause cycle
By multiplying the number pause cycles by the size of the sample test theresult is the number of machine cycles, which are not recorded between twosample tests.
Example: Size of sample test = 5
Number of pause cycles = 10
i.e. in automatic mode between two sample tests there are 5 x 10 = 50machine cycles which are not recorded.
Scaling the xq/R- and the xq/s control charts for individual characteristics
xq/R control chart,xq/s control chartOEG and UEG
After calculating of the upper and lower action limits (OEG und UEG) for themean value xq, the standard deviation s and the range R from a pre-test,scaling of the xq/R and xq/s control charts takes place.
The scale end values entered in line 90.10, 90.12 and 90.14 should be largerthan the corresponding upper action limits.
The scale start values entered in line 90.11, 90.13 and 90.15 should besmaller than the corresponding lower action limits.
The scaling of the control charts must be carried out individually for eachcharacteristic.
Remarks: The calculated upper and lower action limits (OEG und UEG) can also beentered or corrected manually. The manually entered OEG and UEG aredistinguished from the calculated OEG and UEG by colour.
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7.24.2 Calculation and evaluation
In principle the calculations from the pre-test and from an interval are to bedifferentiated.
Calculations from the pre-test
From pre-test For the values recorded in the pre-test the following is calculated for eachcharacteristic:
• the mean value xqq of the individual random sample test averages
• the average sq of the individual sample test deviations
• the average Rq of the individual sample test ranges
• the upper and lower action limits (OEG und UEG) for the above named averages
• the machine capability values cm and cmk
The values xqq, sq and Rq as well as the upper and lower action limits aredrawn in the xq/R and the xq/s control card as horizontal lines.
Machine capability cmk The machine capability is a measurement for short-term influences onproduct variation (minimum requirement cmk = 1.33 or higher)
Influence of capability on quality
Improvement of the machine
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Calculation from the interval (25 sample tests)
From the interval In automatic mode the recording on the xq/R and the xq/s control chartencompasses a maximum of 25 sample tests. The marking of individualsample tests occurs according to time or number of shots. The type ofmarking is selected via softkey "switchover: Time – number of shots".
In addition, sample tests initiated manually via softkey "Manual sample test"are coloured.
After recording 25 sample tests the actual interval from screen page 91.0 istransferred to screen page 91.1 and from screen page 92.0 to screen page92.1 for evaluation. Recording on screen pages 91.1 and 92.0 continues.
Fig. 155: Screen page 91.1: SPC xq/R card last interval
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The following is calculated from the interval:
• mean value of all individual values
• standard deviation
• process capability values cp and cpk
Process capability cpk Process capability is a measurement for long-term influences on productvariation (minimum requirement cmk = 1.0 or higher)
Influence of capability on quality
Improvement of process
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Testing for normal distribution of individual characteristics
Normal distribution Screen page 94 allows a visual test for normal distribution for each individualcharacteristic The Gaussian bell-shaped curve for normal distribution istransformed into a probability line.
Fig. 156: Screen page 94: Probability line
Probability line In connection with specifications for the moulded part (upper and lowerspecification limits in lines 93.05 and 93.06) the probability line indicateswhether the variation lies within specifications.
Fig. 157: Off-centre position of a process
Specifications-middle
Process mean value
USG OSG
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The upper and lower specification limits (OSG and USG) are entered in lines93.05 and 93.06 and drawn as horizontal lines in the diagram on screenpage 94.
7.25 Ejector and core movement while safety gate is open via key switch (option)
DANGER!This key switch must only be used if the design of mould, cores,ejectors and their drives excludes access to shearing and crushingpositions. Failure to follow these instructions can lead to serious injury.
In accordance with EN 201 (4/97) dangerous movements of ejectors andcores must be stopped and prevented while safety gates are open in themould area. This means:
Key switch"Ejector and core movement while safety gate is open"
• The function "Ejector and core movement while safety gate is open" must be switched on via the additional key switch "Ejector and core movement while safety gate is open". This key switch is installed in the front plate of the control unit
• After opening the safety gate, ejector and core movement takes place only as long as the ejector and core input keys are actuated on the control unit or by an optional foot switch.
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7.26 MONOSANDWICH process (option)
General
The monosandwich process represents a simple solution for producing multi-layered moulded parts consisting of skin and core components (sandwichstructures).
Principle
For the monosandwich process an auxiliary extruder is employed which fillsthe injection unit with a skin component through the nozzle opening.
Volumetric feeding is taken over by the stroke measuring system of theinjection unit. The plasticizing stroke (line 40.02) is divided into the two partsof core and skin components. This means: Until the stroke point s1 isreached (line 40.05, column 1) the core component is plasticized via theinjection unit. Then the auxiliary extruder immediately conveys the skincomponent into the nozzle or the front section of the screw via a specialdiverter nozzle until the set plasticizing stroke (line 40.02) is reached. Bothmelts, positioned one behind the other in the screw cylinder, are then injectedinto the cavity.
The maximum quantity of core material is determined experimentally. Byvarying stroke point s1 (line 40.05, column 1) the quantity of the corecomponent can be increased until no core component breaks out of thesurface of the moulded part.
During activated monosandwich operation in operating modes Setting andManual
Fig. 159: Special keys for auxiliary extruder
Monosandwich operation
During monosandwich operation plasticizing takes place with the injectionunit until the switchover point "s1" (rpm "nl". The injection unit at the sametime returns up to limit switch .8-B33. When the limit switch is reached, theauxiliary extruder moves forward to limit switch .5-B202 which in turn allowsthe injection unit to move forward again. When reduced nozzle holdingpressure is reached the auxiliary extruder is activated and used to plasticizewith speed "n2" up to stroke point "s2". The injection unit moves back to thelimit switch which in turn releases the return movement of the auxiliaryextruder. Then the injection unit moves forward with reduced pressure (limitswitch .8-B32). When clamping pressure is built up switchover to nozzleholding pressure takes place.
When monosandwich operation is switched off, plasticizing takes place viathe injection unit only. The switch-over valve is not activated. Monitoring ofmovement strokes is not activated.
If monosandwich is activated and screw release is given plasticizing can takeplace with the auxiliary in manual with key "Plasticizing - auxiliary extruder".
Move forward auxiliary extruder
Return auxiliary extruderAuxiliary extruder
Heating ON
Heating OFF
Plasticizing -auxiliary extruder
Temperatur reduction -auxiliary extruder
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Screen relevant keyboard
Selection: Injection unit / auxiliary extruder; applies only to screen page 30.0"Temperatures – injection unit" and "Temperatures – auxiliary extruder".
Via key "Select: Injection unit/auxiliary extruder" the temperature side for theauxiliary unit is selected.
When monosandwich operation is not active these values are not linked withinjection unit release.
Heating of auxiliary extruder can be switched on with key "Heating on –auxiliary extruder" and switched off with key "Heating off – auxiliary extruder".Temperature reduction for auxiliary extruder is entered with key"Temperature reduction – auxiliary extruder", if a reduction temperature isentered.
ATTENTION!• When monosandwich operation is active, plasticizing is only
possible when screw release from injection unit and auxiliary extruder exists.
• The auxiliary extruder can only be moved forward when the safety gates are closed.
• In operating modes semi-automatic or automatic the auxiliary extruder remains forward under pressure during the filling process. "Auxiliary extruder rear" monitoring remains active even when monosandwich operation is switch off. If the limit switch is reached when the auxiliary extruder returns, the unit stops, again actuating the key "Auxiliary extruder return" allows movement up to the limit stop.
Entering parameters for monosandwich operation.
Temperatures,Screen page 30.0:
Temperatures for the injection unit and the auxiliary extruder are entered viascreen page 30.0 in connection with key "Select: Injection unit/auxiliaryextruder".
Plasticizing process,Screen page 40.0:
Line 40.05, column 1 Plasticizing stroke s1 for injection unit (core component)
Line 40.06, column 1 Screw speed nl for injection unit.
Line 40.05, column 2 Total plasticizing stroke (input in line 40.02) = plasticizing stroke s1 (corecomponent) + plasticizing stroke (skin component)
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Running and operating the machine
Line 40.06, column 2 Screw speed n2 for auxiliary extruder.
Notes: • Possible nozzle movements during monosandwich operation:
– Nozzle retraction immediately after injection (line 49.02, value 0) or– Nozzle retraction delayed after injection (line 49.02, value 1)
• Nozzle retraction time (line 49.10) must be set long enough to allow limit switch .8-B33 to be reached during nozzle retraction.
Messages during monosandwich
– "Injection unit not in correct position"Injection unit is not in rear position to allow auxiliary extruder to moveforward (limit switch .8-B33)
– "Screw release auxiliary extruder missing"Required temperatures for auxiliary extruder not yet reached
NoteIn the event of a fault during the movement sequences for filling the injection unit by the auxiliary extruder, the respective unit should be moved into its rear position and checked if the limit switches are correctly triggered.
s1 s20Core component Skin component
Line 40.05Column 1
Plasticizing strokeLine 40.02
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Running and operating the machine
7.27 AIRPRESS gas injection technique (GIT) from Ferromatik Milacron (option)
Process and system technology
Identifying characteristic of airpress process is filling the mould cavity withtwo fluids. The one fluid consists of a plastic melt, the other a gas, generallynitrogen N2. Through gas injection, which takes place via a special machinenozzle or a mould nozzle, cavities can be deliberately created in the mouldedpart.
Airpress interface The injection moulding machine is connected to gas pressure system via anelectric 24 pole interface. The pressure setting/control takes place 1.) via the gas pressure system or2.) via the machine control.
External system technique In the first instance, only a start signal is given by the injection mouldingmachine for gas injection. The parameters for gas injection are set on the gaspressure controller.
Via screen page of injection moulding machine
In the second instance, parameter input takes place via special screen page48.0 "Injection unit: Airpress II/III". Gas pressure control can take placeexternally (gas pressure system with pressure control module) or internallyvia the injection moulding machine (gas pressure system without pressurecontrol module).
Input options on screen page 48.0 include Airpress II – GIT according to theair jet process – as well as Airpress III – a mass back-pressure processpatented by Ferromatik Milacron – by which the melt forced back into thefront of the screw by means of gas pressure.
Airpress II (operating mode 2, line 48.03, value 2)
The process begins with the melt being injected into the cavity. When themould has been filled to between 50 and 95 %, the gas injection phasebegins via a mould nozzle. The gas fills the cavity by driving the melt frontfurther forward. This deliberately creates cavities in the moulded part. Duringgas injection, gas must be prevented from entering the front of the screweither by means of a shut-off nozzle or by melt dwell pressure. When thecavity is completely filled gas dwell pressure continues until the moulded parthas become dimensionally stable. When the melt has solidified, gas pressureis released by letting the gas escape into the environment or by recycling acertain portion (up to 90 %) via the machine or mould nozzle.
Airpress III (operating mode 3, line 48.03, value 3)
During the Airpress III process the cavity is first completely filled. After aspecific melt dwell pressure phase, with which thin-walled sections of themoulded part are compensated, gas injection begins. Gas pressure causesthe excess melt to be forced back into the front section of the screw. Thescrew return movement caused by the gas pressure is monitored and afterreaching a certain stroke point the mould or the machine nozzle is closed.This is followed by a gas dwell pressure phase, in order to compensate formaterial shrinkage, and then gas pressure release.
Setting for the Airpress process
Operating mode,Line 48.03
In this line the Airpress process to be operated with is selected: Value 2: Airpress II process (air jet process) Value 3: Airpress III process (mass return pressure process)
Airpress type, line 48.04 In this line the gas pressure system is defined. The input controls the"Airpress release" signal set by the machine.
Airpress start with phase, line 48.02
In this line the injection phase is set; after the expiry of this phase gasinjection takes place.
ATTENTION!So that the stroke points for screw return movement are acknowledged,the following condition must have been met: Cushion must be smaller than the stroke points entered in line 48.10.
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Running and operating the machine
Time monitoring 1 to 4,line 81.7.02 to 81.07.05
applies only to Airpress III For tolerance monitoring of screw return movement, a monitoring time can beentered on screen page 81.7 in line 2 "Time monitoring 1" up to line 5 "Timemonitoring 4". After setting the reference values, the necessary actual valuesfor reaching stroke point 1 and 4 can be traced and monitored in the trenddiagram.
Gas injection phase
The parameters for the gas injection phase are entered in lines 48.10 to48.16. The required values entered in these lines are effective for the nozzleselected via softkeys "GID-nozzle 1", "GID-nozzle 2", "GID-nozzle 3", and"Nozzle 4".
Delay time,Line 48.11
Delay time starts with start of Airpress (line 48.02). After expiry of delay timethe respective nozzle is activated for the injection of gas.
Stage 1 to 5, lines 48.14 to 48.16
The gas injection phase can be subdivided into five stages. For each stagegas pressure, action time and ramp time must be entered.
Ramp time Via ramp time it is set in which time the gas pressure entered is built up/released.
Action time Action time determines the duration of gas injection.
Pressure Gas pressure, is built up by the gas pressure system via the pressure controlmodule.
Closing mould nozzle with stroke point, line 48.10
applies only to Airpress III, With the stroke points (line 48.10) entered, screw return movement ismonitored. Gas pressure causes the melt to be forced back in the direction ofthe sprue or front of the screw. This causes return movement of the screw.After reaching the set stroke points (screw positions) the mould nozzle isclosed.
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8 Elimination of faults
8.1 Step list
The Steps described are part of the main programme of the machine control.Steps which are not listed belong to special programmes and aredocumented in the corresponding description of the special programme.
Remedy: Check temperature actual values and tolerances
Fault: "Plasticizing stroke not reached", "Plasticizing stroke exceeded". Themachine will stop on this step, when after initiating semi- or automaticoperation modes by pressing key "Start", the above mentioned faults haveoccurred.
Remedy: Check material feeding, purge screw cylinder in manual operation
Remedy: Select operation mode setting; move ejector to position 0 by activating key"Ejector forward"
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Fault: "Electronic eye/production scale"
Remedy: Check if the part ejects correctly
Fault: "Ejector platen safety"
Remedy: Move ejector forward; check whether the ejector platen is dirty and ifnecessary blow it clean.
Step 7
Fault: "Mould safety"
Fault: "Mould safety repetition"
Remedy: Check if the part is properly ejected; if necessary clean mould surfaces
Step 10
Fault: "Plasticizing stroke exceeded"
Remedy: Manual purging
Fault: "Plasticizing stroke not reached"
Remedy: Check material feed
Step 12
Fault: "Clamping pressure monitoring time"
Remedy: Select operating mode manual; open mould; close mould and check ifrequired clamping force builds; in case of fault there is a defect in either thehydraulics or electronics
Step 15
Fault: "Screw release missing"
Remedy: Check temperature actual values and tolerances
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Fault: "Mould heating release missing"
Remedy: Check temperature actual values and tolerances
Step 16
Fault: "Nozzle holding pressure not reached"
Remedy: Check pressure switch .5-F1; adjust pressure switch until the machinecontinues, or check if required values were entered in lines 49.11 and 49.13
Step 18
Fault: "Clamping force smaller than 80 %"
Remedy: Check consistency of clamping pressure during cycle; there is a leakage ifclamping pressure drops
Step 19
No message
Step 26
Fault: Waits till cooling time has expired
Step 42
Control, if opening width is reached, no message; fault possible during offsetproblem
Remedy: Check mould position; move machine open in setting mode; manual; openand close machine and check position; check opening stroke in line 51.02; ifthis appears often, there is a hydraulic or an electronic defect
Step 43
No messages, cycle interference possible
Remedy: If ejector does not reach forward stroke point check setting
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Step 56
Control, if opening width is reached, no message; fault possible during offsetproblem
Remedy: Check mould position; move machine open in setting mode; manual; openand close machine and check position; check opening stroke in line 51.02; ifthis appears often, there is a hydraulic or an electronic defect
Step 61
Fault: "Pressure switch .5-F1 does not open"
Remedy: Adjust switch until machine switches; check cables; switch may be defective.
Step 62
Fault: "Oil temperature out of wide tolerance"
Remedy: Check if cooling water circuit is functional
Fault: "Max. tolerance deviations"
Remedy: Check settings on screen pages 41/42/43/81.1-81.5
Step 63
Fault: "Electronic eye/production scale"
Remedy: Check if moulded part has dropped; trigger electronic eye anew
Fault: "Cycle time exceeded"
Remedy: Refer to Alarm page for diagnosis of further faults
Fault: "Plasticizing time unit 1 exceeded"
Remedy: Check material feeding; check back pressure
Fault: "Screw rpm measurement interrupted"
Remedy: Replace rpm counter
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Elimination of faults
Fault IQT: "Subtracting shot counter equals zero"
Remedy: Set the subtracting shot counter in lines 21.12 and 21.15.
Note: The diagnostics screen pages 87 to 89 are described in the service manual.Screen page 87.0 contains a far more detailed diagnosis of the actual state ofthe sequence programme than step information.
NOTE
The diagnostics screen pages 87 to 89 are described in the service manual.
Screen page 87.0 contains a very detailed diagnosis of the actual status of the programme sequence.
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8.2 Fault diagnosis
Actuate emergency-off key
When this message appears, the emergency-off lamp on the machine lightsup
Emergency-off function causes:
• Immediate cycle interruption
• Shut down all movement
• Motor and heating switching-off
• Opening of the hydraulic nozzle
Safety gate open
This message causes:
• Mould movement to stop
• Core pulling movement to stop
• Ejector movement to stop
Open nozzle guard
When the nozzle guard is open:
• The injection unit can be moved back but not forward.
• Purging is not possible
• If the nozzle guard is opened after injection, the cycle will be completed and the machine stops on step 19.0.
Screw release missing
Screw release occurs four minutes after all heating controllers have reachedthe lower value of the set narrow tolerance range at the same time. If acontroller is switched off, the screw release disappears.
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Mould safety
The machine is opening to mould opening width, core pulling and ejectorprogrammes are running. Parallel to this message, the emergency-off lamp isflashing. The monitoring time set in line 50.15 has elapsed before the strokepoint "Start clamping force build-up" is reached.
Possible reasons:
• Part is stuck in mould
• Mould safety pressure too low
• Only one mould half heated
• Mould guide bolt not lubricated, etc.
Oil level too low
The oil level in the tank is monitored by the float switch .1-F30. This messagecauses:
• Motor shut-down
• Blocking of all movements
• Heating to shut down or starts temperature reduction
• Emergency-off light blinks
• Opening of the hydraulic nozzle
Oil temperature out of narrow/wide tolerance
The oil temperature is kept to ca. 45° C by the water shut-off valve at theoutlet of the cooler. If the oil temperature rises above this value, the message"Oil temperature out of narrow tolerance" appears from 55°C on withouthaving an influence on cycle sequence.
Oil temperature of 60°C causes:
• Message "Oil temperature outside wide tolerance" appears
• Started cycle is completed
• Blocking of all movements
• Opening of the hydraulic nozzle
• Emergency-off light blinks
Oil temperature of >65°C causes: Pump motor shut-down
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Oil filter contaminated
The Filter insert must be replaced after 1500 operating hours. If an exchangedoes not take place, the fault message "Oil filter contaminated" appears whenthe filter becomes too contaminated; however, the machine continuesoperating.
Motor safety responds
An overload of the motor causes:
• Motor shut-down
• Blocking of all movements
• Opening of the hydraulic nozzle
• Emergency-off light blinks
Checksum fault
This fault may occur during reading in of the data carrier. Possible causes:
• Data carrier not inserted (not all connections made)
• Data carrier was removed during the reading in/out process
• Faulty data carrier
A safety circuit prevents writing on the data carrier or the selection of page 10during the aforementioned causes.
This prevents storage of wrong or faulty data when writing on data carrier.
Removal of fault:
• Re-formatting data carrier
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Elimination of faults
Plasticizing stroke exceeded
When plasticizing stroke is exceeded or screw suck-back occurs by morethan 7mm:
• No injection
• Machine moves to opening width, ejector and core pulling programmes run down
• Emergency-off light blinks
For removal of fault see Chapter 7.9.6 "Plasticizing time monitoring"
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8.3 Source of faults when installing mould
Mould height too low:
Consequence: The machine does not close completely during setting operation or does notmove up to the mould fixed on nozzle side, because of the stroke limitation ofthe piston.
Remedy: Install spacer or washer
Mould safety pressure set too low (line 50.12)
Consequence: • The mould does not close
• Mould safety time is exceeded
• The machine stops at mould opening width and the fault message "Mould safety" appears on screen.
Remedy: Increase mould safety pressure
Monitoring time for mould safety set too short (line 50.15)
Consequence: Mould safety time should be selected 0.3 – 0.5 seconds higher than the timerequired (see actual value line 50.15). If mould safety time is set too short, themachine moves to opening width and the mould safety message appears.
Remedy: Increase mould safety time
Opening and closing speeds set too high(screen pages 50.0 and 51.0)
As a matter of precaution, lower values should be selected for the openingand closing speeds (when installing the mould). These values can then begradually optimized.
Ejector setting (screen page 52.0)
Carefully work down or check screen page 52.0. An incorrect ejector settingcan cause considerable damage to ejector and mould.
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8.4 Source of faults during injection
Injection time set too short - during stroke-dependent switchover
Consequence: Switchover takes place time-dependent instead of stroke-dependent.
Remedy: Always select a longer injection time than is actually required to reach thenecessary stroke switchover point. (compare Chapter 7.7)
ATTENTION!Injection pressure must be set.
Switchover point is reached too soon - during time-dependent switchover
Consequence: Switchover takes place stroke-dependent instead of time-dependent.
Remedy: Enter injection stroke (smaller values) so that the stroke switchover point isnot reached within the injection time entered (compare Chapter 7.7)
ATTENTION!Injection pressure must be set.
During hydraulic pressure-dependent switchover: Injection pressure is lower than switchover pressure
Consequence: Switchover occurs stroke or time-dependent.
Remedy: Injection pressure must definitely be selected higher than the switchoverpressure entered (compare Chapter 7.7)
Other fault sources: Switchover pressure when not using hydraulic pressure-dependent switchover:
When switchover does not take place pressure-dependent, the switchoverpressure must be set on 160 bar.
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Injection pressure too low
Consequence: Injection pressure is too low for reaching set injection speed.
Remedy: Increase injection pressure so that the required injection pressure is higherby approximately 5 – 20 bar than the actual injection pressure. The pressurereserve guarantees a constant injection speed.
NoteTo obtain practical actual values from the injection phase last used, a cushion (see screen page 42) of at least 3mm and larger should be used.
ATTENTION!Injection pressure must be set.
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checklist
9 Repairs and maintenance
WARNING!Maintenance work carried out on the machine by untrained, unskilledand unauthorized personnel can lead to serious injury and machinedamage as well as rendering all warranty claims void.
Work on the machine must only be performed by adequately trainedand qualified personnel.
The following safety instruction must be adhered to:
• Always switch off the machine when you perform setting, maintenance and repair work, unless it is absolutely necessary that the machine is operating.
• Secure machine against being unintentionally switched on, see Fig. 172, page 2.
• Deactivated or disassembled safety devices must be restored to their proper functioning state and their function tested before releasing the machine for further operation.
• When carrying out setting, maintenance and repair work, block access to the working area if necessary.
• Before carrying out work on the electrical system you must switch off the machine at the main switch and secure it against being unintentionally switched on again:- Disconnect the machine (switch off all circuit breakers)switch off main machine switch
- Secure machine against being switched on- Carry out a voltage free check
• Always enlist a second person for work on current carrying parts who can, in an emergency, cut off the power supply.
• All safety guards and covers, especially the screw cylinder covers, must be correctly re-installed after maintenance work is completed.
• Always use tools appropriate for the job (e. g. insulated tools when working on the electrical equipment).
• Use only genuine parts or spare parts and operating material approved by Ferromatik Milacron Maschinenbau GmbH.
• Observe the prescribed maintenance and service intervals.
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Locking the main switch Always switch off and the main disconnect switch and secure it against beingswitched on when performing setting, maintenance or repair work, unless it isabsolutely necessary that the machine is operating.
Fig. 161: Locking the main switch (circuit breaker)
1 Main switch lever2 Slider with orifice for padlock
To lock the main switch lever, proceed as follows:
• Turn main switch lever (1) to position "0"
• Pull out slider (2)
• Insert padlock into orifice of slider (3)
• Lock padlock and remove key
• Keep key safe until completion of maintenance work
1
2
3
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9.1 Working on the injection unit
To facilitate certain maintenance work, e.g. exchanging screw, the injectionunit must be swivelled out.
WARNING!Danger of burning through very high temperatures in the screw cylinderarea!
When working on the injection unit or on one of its components wearprotective gloves, protective clothing and safety glasses.
9.1.1 Swiveling injection unit out/in
Swivelling out
• Set operation mode selector switch in position "Setting"
• Actuate key "Injection unit return" and move injection unit to its rear position
• Switch off motor (key "Pump motor off")
• Open movable safety gate on injection unit (Fig. 163, Pos. 1)
• Unlock IQT-control unit with clamping lever (Fig. 162, Pos. 1) and swivel out
Fig. 162: Swivel ou IQT-control unit
1 Clamping lever
1
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Fig. 163: Loosening the traverse cylinder rod on the operator side
• Pull out safety pin from socket pins (Fig. 163, Pos. 5)
• Remove socket pin on both sides (Fig. 163, Pos. 3)
• Secure injection unit against being moved by screwing in securing device (M8x80 screw)
Fig. 164: Securing device
• Screw out retaining screws (3 pieces) with Allen key (Fig. 165, Pos. 1 and 2)
• Lossen retaining screws at the pivit point (Fig. 165, Pos. 3)
2
3
4
1
5
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Fig. 165: Injection unit fixing screws
1 Retaining screws injection unit front2 Retaining screws injection unit rear3 Retaining screw injection unit rear as pivoting point
• Swivel out injection unit up to the mechanical stop in the direction of the operator side by pulling at the screw cylinder support (Fig. 166, Pos. 1)
Fig. 166: Injection unit front
1 Screw cylinder support2 Thread for storing securing device
1
1
2 3
1
2
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Swivelling in
• Swivel injection unit back up to the mechanical stop
ATTENTION! Remove securing device from injection unit and store (see Fig. 166,Pos. 2)!
• Screw in retaining screws (3pieces) but do not tighten
• Secure traverse cylinder piston rods with socket pins to the stationary mould clamping platen
• Tighten retaining screws (4 pieces including retaining screw at pivoting point)
• Swivel back IQT-control unit and lock it
• Switch on motor
• Close safety gates
• Actuate "Start" key
• Put operating mode selector switch in position "Manual"
• Mould is installed and clamping pressure built up
• Move injection unit forward by pressing key "Injection unit forward"
• Check nozzle and mould sprue bushing alignment
• If necessary align injection unit over the cam follower (only for K-TEC 85 - K-TEC 155) or over the adjusting screws in the supports (see Chapter 5.3.4 "Aligning nozzle on sprue bushing in the mould")
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9.1.2 Swivelling injection unit out(injection unit of international size 970, optional on K-TEC 155)
Fig. 167: Injection unit with linear guides
1 Socket pin2 Nozzle body3 Shipping brackets4 Hopper with evacuation device5 Set screw6 Retaining screws (not visible in illustr.)7 Retaining screw at pivot point8 Screw cylinder support9 Cam follower
8
4
59
7
12
3
6
5
6
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ATTENTION!Danger of burning when screw cylinder is hot!
When working on the injection unit or on one of its components wearprotective gloves, protective clothing and safety glasses. Failure tofollow these instructions can lead to injury.
Procedure • Set operation mode selector switch in position "Setting"
• Press key "Injection unit return" and move injection unit into its rear position
• Switch off motor
• If screw is to be exchanged after swivelling out:
– Loosen front heater band on the screw cylinder– Remove nozzle body
• Pull out socket pins with which the traverse cylinder piston rods are secured to the stationary mould clamping platen
• Secure injection unit against moving by installing transport brackets
• Loosen reatining screws (3 pieces) with a 17 mm open-ended spanner;Retaining screw at the pivot point remains tightened
• Unlock and swivel out the IQT-control unit
• Remove cowling between IQT-unit and stationary mould clamping platen (required for pulling the screw)
• Swivel out injection unit up to the mechanical stop in the direction of the operator side by pulling at the screw cylinder support
Returning to injection position
• Swivel injection unit back up to the mechanical stop
ATTENTION! Remove transport brackets from injection unit and store!
• Do not yet tighten retaining screws (3pieces)
• Secure traverse cylinder piston rods with socket pins to the stationary mould clamping platen
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• Tighten retaining screws (3 pieces)
• Install nozzle body: (see Chapter 9.1.3 and Chapter 9.1.4)
• Loosen front heater band on the screw cylinder
• Install cowling between IQT-unit and stationary mould clamping platen
• Swivel back IQT-control unit and lock it
• Switch on motor
• Close safety gates
• Actuate "Start" key
• Put operating mode selector switch in position "Manual"
• Mould is installed and clamping pressure built up
• Move injection unit forward by pressing key "Injection unit forward"
• Check nozzle and mould sprue bushing alignment
• If necessary align the injection unit over the cam follower ort he adjusting screws in the supports
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9.1.3 Changing nozzle body (flanged nozzle body)
CAUTION!Danger from faults and material damage when using unsuitable nozzlesor fixing screws.
Only nozzles and fixing screws approved by Ferromatik Milacron mustbe used. The specified torque settings must be observed.
WARNING!Danger of burning through very high temperatures in the screw cylinderarea!
When working on the injection unit or on one of its components wearprotective gloves, protective clothing and safety glasses.
• Remove heater bands and thermocouples and optional equipment if necessary
• Screw out retaining screws and remove nozzle body
1 2 3 2 4
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Installing nozzle body
ATTENTION!• Before re-installing check sealing surfaces for contamination or
material residue and thoroughly clean if necessary
• When working on sealing surfaces gentle tools must be used. Otherwise sealing surfaces and edges may sustain damage.
• Coat sealing surfaces with high temperature compound
NotesThe installation instructions for flanged nozzle bodies also apply:
• when installing a screw cylinder with a flanged adapter, into which a needle shut-off nozzle is screwed.
• when installing a nozzle body with a rotary slide valve, which is flanged onto the screw cylinder.
Procedure • Check sealing surfaces for contamination or material residue and thoroughly clean
• Check sealing surfaces with blueing paste (see Chapter "Control of sealing surfaces with blueing paste")
• Coat retaining screws with high temperature compound (e.g. Rivolta G.W.F. anti-seize compound)
• Fit nozzle body to screw cylinder with 4 retaining screws
• Install rest of retaining screws
• Lightly and evenly cross-tighten retaining screws so that nozzle body fits tightly
• Install nozzle heater bands and temperature sensor
• Switch on cylinder heating (250°C)
• Ensure temperature equalization between screw cylinder and nozzle body.
• Cross-tighten retaining screws to specified torque evenly in several stages (see adjacent illustration)
– 1. stage with 50 % of required torque– 2. stage with 75% of required torque– 3. stage with 95% of required torque– 4. stage with 100% of required torque
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• Check nozzle heater bands and temperature sensors for proper seating and retighten
Installing nozzle tip • If the nozzle tip was removed:
– Check sealing surfaces for contamination or material residue andthoroughly clean
– Check sealing surfaces with blueing paste (see Chapter "Control ofsealing surfaces with blueing paste")
– Coat thread of retaining screws with high temperature compound (e.g.Rivolta G.W.F. anti-seize compound)
– Screw in nozzle tip with ring spanner– Ensure temperature equalization between nozzle tip and body
(250°C)– Tighten nozzle tip to torque setting
Specified torque for retaining screws
Dimensionof retaining screws
Torque value [Nm]
M12 120
M16 295
M20 580
M24 1000
M30 2000
Torque values for nozzle tips
Thread[mm]
Channel diameter[mm]
Torque value [Nm]
M30x1.5 8 140
M48x2 12 420
M30x1.5 12 210
M48x2 16 600
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Check sealing surfaces with blueing paste
NoteClean surfaces thoroughly before checking with blueing paste. All contamination leads to faulty control result.
• Thoroughly clean sealing surfaces
• Thinly coat sealing surfaces on nozzle body and nozzle tip with blueing paste.
• Install nozzle body an lightly tighten retaining screws (tightening to torque value is also possible) or screw in screw tip and tighten lightly.
• Remove nozzle body/tip.
• There must be an even colour spread of the paste on the sealing surface of the screw cylinder and nozzle body.
• Remove blueing paste from sealing surfaces with spirit.
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9.1.4 Changing nozzle body (screw-in nozzle body)
CAUTION!Danger from faults and material damage when using unsuitable nozzlesor fixing screws.
Only nozzles and fixing screws approved by Ferromatik Milacron mustbe used. The specified torque settings must be observed.
WARNING!Danger of burning through very high temperatures in the screw cylinderarea!
When working on the injection unit or on one of its components wearprotective gloves, protective clothing and safety glasses.
Fig. 169: Screw-in nozzle body
1 Nozzle tip2 Heater band3 Thermocouple
Removal of nozzle body
• Heat screw cylinder to 250°C
• Switch off cylinder heating
• Remove heater bands and thermocouples and optional equipment if necessary
• Screw out nozzle body
1 2 3
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Installing nozzle body
CAUTION
• Before re-installing check sealing surfaces for contamination or material residue and thoroughly clean if necessary
• When working on sealing surfaces gentle tools must be used. Otherwise sealing surfaces and edges may sustain damage.
• Coat sealing surfaces with high temperature compound
Procedure • Check sealing surfaces for contamination or material residue and thoroughly clean
• Check sealing surfaces with blueing paste (see Chapter "Control of sealing surfaces with blueing paste")
• Coat thread of nozzle body with high temperature compound (e.g. Rivolta G.W.F. anti-seize compound)
• Screw nozzle body into screw cylinder and tighten lightly
• Install nozzle heater band and temperature sensor
• Switch on cylinder heating (250°C)
• Ensure temperature equalization between screw cylinder and nozzle body.
• Tighten nozzle body to torque setting
• Check nozzle heater band and temperature sensor for proper seating and retighten
Torque values for screw-in nozzle body
Thread[mm]
Screw diameter [mm] Torque value [Nm]
M48x2 18 950
M48x2 25 1200
M48x2 30 1700
M58x3 35 2900
M58x3 40 3300
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Installing nozzle tip • If the nozzle tip was removed:
– Check sealing surfaces for contamination or material residue andthoroughly clean
– Check sealing surfaces with blueing paste (see Chapter "Control ofsealing surfaces with blueing paste")
– Coat thread of retaining screws with high temperature compound (e.g.Rivolta G.W.F. anti-seize compound)
– Screw in nozzle tip with ring spanner– Ensure temperature equalization between nozzle tip and body
(250°C)– Tighten nozzle tip to torque setting
Check sealing surfaces with blueing paste
NOTE
Clean surfaces thoroughly before checking with blueing paste. Allcontamination leads to faulty control result.
• Thoroughly clean sealing surfaces
• Thinly coat sealing surfaces on nozzle body and nozzle tip with blueing paste.
• Screw in nozzle body/tip and tighten lightly
• Remove nozzle body/tip
• There must be an even colour spread of the blueing paste on the sealing surface of the screw cylinder and nozzle body.
• Remove blueing paste from sealing surfaces with spirit
Torque values for nozzle tips
Thread[mm]
Channel diameter[mm]
Torque value [Nm]
M30x1,5 8 140
M48x2 12 420
M30x1,5 12 210
M48x2 16 600
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9.1.5 Changing screw and screw tip
WARNING!There is danger of burning during nozzle and screw change, due to veryhigh temperatures in the injection unit area and the leakage of hotmaterial.Always wear suitable protective clothing when working on the injectionunit or its components; this especially includes heat resisting glovesand suitable safety glasses etc.
WARNING!Danger of injury due to squashing and knocking, and damages to theplant due to inattentiveness!Always work with extreme care, to avoid injuries due to squashing,knocking, and damaging the plant.
ATTENTION!• The screw becomes immovable when cooling material solidifies in
the screw cylinder.
• The screw and the screw tip must be removed in a hot state.
• Use only screw cylinders and retaining screws approved by Ferromatik Milacron.
• Always use suitable lifting devices (e.g. chains, straps or ropes) with adequate load-bearing capacity for moving loads and observe the correct fixing points on the load.
• At least 2 persons are required for changing the screw and screw tip, due to the weight of parts and the working procedure.
Notes• Only change screw and screw cylinder in a purged state.
• The screw cylinder has processing temperature (screw release is given). When changing to a screw cylinder with a different diameter, the actual screw cylinder parameters must be entered on screen page 19.1.
• Motor and heating must be switched off.
• After calling up screen page 49 or 19 select page 19.1 via softkey "Cylinder definition".
• Activate screw change programme for screw and screw cylinder change
• Operation mode selector switch in position "Setting"
• Pressure and speed are firmly fixed for this function
Screw change
Nozzle bodyremoving
• Loosen cowling at the IQT (the screw will be pushed through here later)
Fig. 170: Cowling on the IQT
1 Retaining screws
• Swiveling out IQT- see Chapter 9.1.1 "Swiveling injection unit out/in"
• Pull nozzle heater band plug
• Remove heater band and nozzle temperature sensor
• Disassembling nozzle body (see Chapter 9.1.3 "Changing nozzle body (flanged nozzle body)" or see Chapter 9.1.4 "Changing nozzle body (screw-in nozzle body)")
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Loosen screw from injection unit
Prerequisite: Programme "Screw change" is activated.
Fig. 171: Screw change
1 Flange half2 Retaining screws
• Press key "Plasticizing": Move injection cylinder piston into rear end position
• Remove flange halves (Fig. 171, Pos. 1) of the screw fixture by loosening the retaining screws (Fig. 171, Pos. 2)!
• Actuate key "Injection": Move injection cylinder piston into forward position
• Press key "Plasticizing": the multi-spline profile of the screw is pulled out of the spline adapter
• Pull screw out of screw cylinder
2
2
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Exchanging screw tip / non-return valve
Removal • Loosen the screw tip by slightly knocking on the left tooth flank with a plastic hammer (Attention! Left-handed thread).
Notes• Observe the position for installing the locking ring!
• Hand-tighten screw tip only !
• Observe the instructions of the lubricant manufacturer!
• Thoroughly check the thread on the screw tip and screw as well as the sealing surfaces for contamination or material residue and clean thoroughly
• Coat the screw tip and screw with high-temperature compound (Rivolta G.W.F anti-seize compound and lubricant)
• Screw in the screw tip together with the non-return valve (attention: left-hand thread!)
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• Ensure temperature equalization between screw tip and screw.
• Tighten screw tip by hand
• Check if breaker ring lies flush on the front face of the screw
• Try turning the breaker ring. The screw tip is sufficiently tight when the breaker ring can no longer be turned.
Installing the screw
• Slide screw into screw cylinder
• By pressing key "Injection" move spline adapter step by step up to the screw
• Turn screw by hand to guide it into the spline adapter.
• Insert screw up to the mechanical stop in the spline adapter
• Install flange halves (observe correct seating) and only slightly tighten fixing screws
• Installing nozzle body (see Chapter 9.1.3 and Chapter 9.1.4)
• Enter value 0 on screen page 49, line 15
• Centrally align screw in cylinder; to do this
– Open hopper and turn screw slowly (50 min-1). An even material filmforms around the screw
• Cross tighten retaining screws on flange halves to specified torque (see Chapter 10.2)
Installing the nozzle
ATTENTION!• Do not coat sealing surfaces with compound!
• Observe the instructions of the lubricant manufacturers
• Retaining screws for flanged nozzles are handled in like manner
• Use only "Unbrako" retaining screws, strength class 12.9!
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NoteUse only nozzle tips, nozzle bodies, screw cylinder and retaining screws with our specifications.
Before installing nozzle tips and nozzle bodies, the external must be cleanedand coated with high-temperature compound (Rivolta G.W.F. anti-seizecompound and lubricant).
ATTENTION!If this procedure is not followed, nozzle tip, nozzle body or screwcylinder could sustain damage. Later disassembly of nozzle tip and nozzle body is very difficult.
• Clean internal thread on nozzle body and screw cylinder
• Screw nozzle tip into nozzle body and nozzle body into screw cylinder and tighten or fix with flange (see Chapter 9.1.3 and Chapter 9.1.4)
• Install nozzle heater bands and temperature sensor
• Set screw cylinder heating on 250°C and switch on
• After obtaining screw release and a waiting time of more than 15 minutes retighten nozzle body and then nozzle tip. Also retighten nozzle heater bands
9.1.6 Screw cylinder change
WARNING!There is danger of burning during nozzle and screw change, due to veryhigh temperatures in the injection unit area and the leakage of hotmaterial.Always wear suitable protective clothing when working on the injectionunit or its components; this especially includes heat resisting glovesand suitable safety glasses etc.
WARNING!Danger of injury due to squashing and knocking, and damages to theplant due to inattentiveness!Always work with extreme care, to avoid injuries due to squashing,knocking, and damaging the plant.
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ATTENTION!• The screw becomes immovable when cooling material solidifies in
the screw cylinder.
• Assembly/disassembly must be carried out in a hot state.
• Use only screw cylinders and retaining screws approved by Ferromatik Milacron.
• Always use suitable lifting devices (e.g. chains, straps or ropes) with adequate load-bearing capacity for moving loads and observe the correct fixing points on the load.
• At least 2 persons are required for the work process, due to the weight of parts and the working procedure.
Notes• Only change screw cylinder in a purged state.
• The screw cylinder has processing temperature (screw release is given). When changing to a screw cylinder with a different diameter, the actual screw cylinder parameters must be entered on screen page 19.1.
• Motor and heating must be switched off.
• After calling up screen page 49 or 19 select page 19.1 via softkey "Cylinder definition".
• Activate screw change programme for screw and screw cylinder change
• Operation mode selector switch in position "Setting"
• Pressure and speed are firmly fixed for this function
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Removing screw cylinder
Fig. 173: Removal/installation of screw cylinder
1 Lifting device with eyelets2 Tensioning block retaining screws3 Cooling water hoses for feedthroat cooling4 Flange halves of screw fixture5 Retaining screws to the splined adapter6 Screw cylinder fixture locking ring7 Retaining screws to the yoke
NoteScrew cylinder change can be effected with or without the screw installed. The following describes the change with the screw removed.
1 32
6 7 5 4
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• Swivelling injection unit out (see Chapter 9.1.1 "Swiveling injection unit out/in"
• Loosen the screw from injection unit (see Chapter 9.1.5 "Changing screw and screw tip")
• Switch off cylinder heating
• Pull out collective plug for heater bands and thermocouples
• Swivel back the hopper
• Switch off feed throat cooling, relieve cooling water circuit and remove water hoses (Fig. 173, Pos. 3)
• Remove hopper
• Install eylets (Fig. 173, Pos. 1) for transporting screw cylinder and secure cylinder to a suitable lifting device
ATTENTION!The screw cylinder could sustain damage if it is tilted during lifting. Liftscrew cylinder carefully and horizontally from its mountings!
• Lift screw cylinder from the yoke taking care not to tilt it
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Installing screw cylinder
• Clean yoke and feedthroat
• Coat contact surfaces on the screw cylinder and cylinder mountings with a thin, even film of compound (Rivolta G.W.F. compound; anti-seize and lubricating compound)
ATTENTION!The screw cylinder could sustain damage if it is tilted during lifting. Liftscrew cylinder carefully and horizontally back into its mountings!
• Set screw cylinder slowly into yoke, taking care not to tilt it
• Align screw cylinder horizontally via cam follower
• Tighten retaining screws on the tensioning block with reduced torque
• Install locking ring and cross tighten fixing screws with reduced torque
• Tighten retaining screws on tensioning block to required torque (MA = 120 Nm)
• Tighten retaining screws of locking ring to required torque(MA = 120 Nm)
• Install hopper
• Connect collective plug for heater bands and thermocouples
• Connect cooling water hoses to feedthroat and switch on cooling system
• Heat screw cylinder to working temperature
• Install screw (see Chapter 9.1.5 "Changing screw and screw tip")
• Check heater bands and temperature sensors for proper seating and retighten
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9.2 Working on clamping unit
9.2.1 Replacing the piston rod seals; replacing the pressure bolts
Fig. 174: Replacing piston rod seal and pressure bolt
If the clamping cylinder piston rod (1) is separated from the pressure bolt (2)or the pressure plate from the moving mould clamping platen (4) (e. g. duringreplacement of the piston rod seal, during replacement of the pressure bolts(3) for changing mould installation height), the following must be observedduring assembly:
• The assembly of clamping cylinder piston rod with pressure plate or moving mould clamping plate must only be carried out while clamping cylinder piston rod is fully moved in
• To indicate manufacturing tolerance pressure bolts are marked with stamped numbers. When replacing pressure bolts, only pressure bolts with equal markings must be installed e. g. "0", "1", "2" or "3"
NoteDue to the weight of the clamping cylinder piston rod, the piston in the clamping cylinder housing is not centric when the piston rod has been moved out. If the assembly is carried out while the clamping cylinder piston is moved out, it will jam in the cylinder housing.
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9.2.2 Automatic central lubrication (option)
The automatic central lubrication lubricates the slide bearings on the fourrods with grease. The lubricating system consists of pump, main and subdistributor as well as lubrication lines.
The lubrication interval is determined via the IQT control unit of the injectionmoulding machine.
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9.3 Working on the hydraulic system
9.3.1 Safety measures while working on the hydraulic system
DANGER!Uncontrolled machine movements due to unintentional switching on ordue to residual pressure in the hydraulic system can lead to serious oreven fatal injuries.
Before carrying out work on the hydraulic system you must:
• Move mould to opening width to render system pressureless
• Check that system is pressureless
• Switch off the machine and secure it against being unintentionally switched on (see Fig. 172, page 2)
• Ensure that only qualified, adequately trained personnel familiar with the dangers and are authorized to perform the work
WARNING!Escaping hydraulic oil (especially under high pressure) can causeburning, poisoning or injuries through slipping!
Always wear suitable protective clothing (gloves, boots, face visor etc.).
9.3.2 Storing and disposing of hydraulic oil
PROTECTING THE ENVIRONMENT!When using, storing and disposing of hydraulic oil, cleaning agents andtoxic materials, legal requirements must be observed.
Waste products such as remaining oil, cleaning agents, dirty water etc.,as well as saturated cloths must be disposed off according to currentlyvalid environmental protection regulations and delivered to authorizedreceiving stations. Contact the relevant authorities for information.
To prevent hydraulic oil, cleaning agents or other toxic materials fromescaping, suitable catching trays are to be employed.
Unintentional spills or leakages of oil, cleaning agents or other toxicmaterials must be immediately cleaned. The penetration of thesesubstances into the floor, into surface water or the drainage systems isto be absolutely avoided. Inform the relevant authorities immediatelywhen such an accident occurs.
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9.3.3 Instructions for exchanging hydraulic components
When exchanging hydraulic components the following must be observed:
• When changing a damaged component, thoroughly flush the hydraulic system before installing the new component and refill with new hydraulic oil after new component is installed Filling with hydraulic oil
• Cover or close openings to the hydraulic system to prevent contaminating the hydraulic system.
• When cleaning hydraulic components with air, use only dry, oil-free air
• Cleaning new components
• When sealing pipe thread with Teflon tape, keep the first internal thread free
• Use only oils and lubricants recommended by Ferromatik Milacron
ATTENTION!Never us sealing compound to seal a pipe thread, since it could settle inthe hydraulic valves and interfere with their function.
Use only suitable sealing materials such as Teflon tape.
9.3.4 Recording of work on the hydraulic system
The following data related to work on the hydraulic system is to be recordedin the machine's maintenance documents:
– Date work carried out– Type, class and manufacturer of hydraulic oil when refilling or
changing– results of laboratory analyses– Complete documentation about replacement or repair of components
of the hydraulic system– Type of work, such as additional filtration and cleaning, or change of
filter elements, hydraulic oil change, cleaning of system and materialsused
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9.3.5 Oil maintenance procedure
WARNING!Contact with hydraulic oil, cleaning agents or other toxic materialscould cause injury to the skin, the eyes and the respiratory tracts.
Avoid direct skin contact with hydraulic oil or toxic materials, alwayswear protective clothing (gloves, boots, face visor etc.)
If contact with skin or eyes occurs, thoroughly clean skin and rinseeyes with copious quantities of water and then contact a doctor withoutdelay.
DANGER!Failure to observe the necessary safety directives when working on thehydraulic system can lead to serious even fatal injuries.
When working on the hydraulic system all measures related to safetyand environment stated in chapters Chapter 9.3.1 and Chapter 9.3.2must be observed!
ATTENTION!The use of unsuitable hydraulic oil can adversely affect proper and safemachine function.
Use only brand-new hydraulic oil of the right quality for filling andrefilling (see Chapter 10.3.1 "Hydraulic oils").
The first oil maintenance measure should take place at the latestafter200 operating hours.
Oil purity can only be ensured by the exclusive use of filter elements specifiedby Ferromatik Milacron.
The guarantee for failed hydraulic components is conditional on carrying outproper oil maintenance measures.
Oil maintenance measures include:
• Oil purification (see "Oil purification intervals" on page 32)
• Oil change after a set number of operating hours (see "Oil-change intervals" on page 32)
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• Change of oil filter (see "Change of oil filter" on page 33)
• Specific checks on the hydraulic system (see "Checking the hydraulic system" on page 35)
• Determining oil quality by oil analysis (see "Checking oil condition" on page 35)
Oil purification intervals
Oil maintenance measures are to be carried out after the first 200 operatinghours and then after every 200 operating hours. To purify the hydraulic oil a1µ flushing filter element is installed in the medium pressure filter. Theservice time of the flushing filter element is approximately 200 hours.
After the flushing process the 3µ filter element is to be installed in the by-passoil filter (see Chapter "Change of oil filter"). The reuse of the oil is possibleafter laboratory analysis.
Part number for ordering 3µ filter element 0107993Part number for ordering 1µ filter element 0008174
The oil filter filters out normal contaminants. When the filter is contaminated acorresponding message appears on screen. However, the machinecontinues to operate.
Oil-change intervals
The first oil change should take place at the latest after 7500 operatinghours.
ATTENTION!When changing the oil a thorough cleaning of the tank rooms isespecially important.
The guarantee for failed hydraulic components is conditional on carrying outproper oil maintenance measures.
Oil purity can only be ensured by the exclusive use of oil filter elementsspecified by Ferromatik Milacron.
An interval of 15000 operating hours is possible if the complete hydraulicsystem is regularly purified with a 1µ flushing filter element.
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Change of oil filter
ATTENTION!Oil filters are hazardous waste and must be disposed as such!
NoteIf the filter is prematurely contaminated, the message "Oil filter contaminated" appears on screen; the element must then be replaced. A general filter change should also take place during oil maintenance measures and oil change.
Fig. 175: Oil filter
1 Filter housing2 Retaining ring
Oil filter monitoring The filter is installed in the cooling and filtering circuit. Oil filter monitoringtakes place via a differential pressure switch. It becomes effective at an oiltemperature of 35°C and triggers the screen message "Oil filtercontaminated".
Exchanging thefilter elements
Since the service life of the filter elements is limited and a damaged elementcan cause the failure of components it is necessary to change the filter whenreceiving a fault message. The guarantee for failed hydraulic components isconditional on carrying out filter element changes.
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Procedure: • Open mould to mould opening width
• Switch off motors (key "Motors off")
• Switch machine off at main switch and secure it against being switched on (see Fig. 161, page 2)
• Check pressure gauge M3 (see Fig. 187, page 35, Pos. 2) to see if system is pressureless
• Render hydraulic system pressureless, for S-version machines render accumulator system pressureless
• Open access cover to electric motor
• Set oil catch tray under filter housing
• Unscrew filter housing from retaining ring (see Fig. 186, page 37)
• Change filter element
ATTENTION!Do not clean or reuse filter element!
• Clean accumulated dirt from filter housing (with cleaning solvent or petroleum).
• Ensure that the O-ring and bearing ring in the filter head are not damaged.
• Use only original replacement filter elements from Ferromatik Milacron
• Moisten thread and sealing surface on the filter housing as well as thefilter element O-ring with clean hydraulic fluid
• Set filter element with closed end down into the filter housing
• Screw on filter housing. When tightening the retaining rings the filter element is automatically pushed onto the receiving lug in the filter head.
• Tighten retaining ring by hand (torque value approx. 20 Nm)
• Overtightening does not improve the sealing effect.
• Switch on motor and check filter housing for possible leaks
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Checking the hydraulic system
Fig. 176: Sight glass, oil level
1 Oil level sight glass2 Pressure guage M3
• Regularly check oil level at sight glass (1)
NoteSinking oil level indicates leakage;rising oil level indicates leakage from plate heat exchanger: Water is entering the hydraulic system
• Visually check hydraulic oil for cloudiness and foaming
• Check hydraulic lines and connections for leakages
Checking oil condition
Visually normal looking oil may, through aging, no longer meet requirements.Only an oil test analysis in a laboratory can reveal this.
1
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WARNING!Contaminants in the oil or oil leakages can adversely affect propermachine function, cause environmental damage and represent an injuryrisk.
The cause of contamination in the oil or leakages must be isolated andremoved and if necessary the oil must be replaced.
Causes for falling oil quality – Natural aging– Contamination through solid and liquid substances– Internal leakage– Damage in the hydraulic system, e. g. leaking or damaged seals– Incorrect working temperature of the oil
Causes for oil contamination
– Wear or corrosion in the hydraulic system– Cavitation of the drive unit– Unclean repair and maintenance work (e.g. dust, fibres, metal
shavings, rust, not removing scales when exchanging a pipe)– Using dirty containers for storing or filling– Intrusion of dust contaminants when topping up or exchanging– Particles which enter the oil due to faults, such as pump damage– Intrusion of dirt via faulty seals of hydraulic cylinders– Damaged or dirty air filter on the oil tank– Particle detachment in the hydraulic system
Causes for air in the hydraulic system
– Leakage on the suction side of the pump– Oil level too low
Signs of contamination through solid foreign matter in the oil
– Worn out valve seats– Worn out nozzles– Sludge in distribution valves, seized hydraulic cylinder– Clogged nozzles– Leakages– Irregular switching of the hydraulic components– Reduced machine performance
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Signs of contamination through air in the oil are
– Surface foam– Air-oil-dispersion (the air bubbles are very small and finely distributed
in the oil)– Uneven or jerky movements– Unusual noises in the pump– Cavitation damage to pumps and seals– Burned seals
Condition of oil When evaluating oil condition, the number of particles is the firstconsideration. For operating Ferromatik Milacron injection mouldingmachines, contamination class 15/12 according to ISO 4406 must not beexceeded. The characteristic number for contamination class according toISO 4406 consists of two factors. These relate to particle sizes > 5 µm and > 15 µm.
Tab. 4: Contamination class according to ISO 4406
Comparison with various standards
Tab. 5: Contamination according to standards
Particle number per 100 ml
Contamination class according to ISO 4406
11 12 13 14 15 16 17
from 1000 2000 4000 8000 16000 32000 64000
to 2000 4000 8000 16000 32000 64000 130000
Contamination class according to
NAS (National Aerospace Standard)
ISO (International Standard Organisation)
SAE(Society of Autom)
6 15/12 3
7 16/13 4
8 17/14 5
9 18/15 6
10 19/16 ---
11 20/17 ---
12 21/18 ---
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9.3.6 Changing plate heat exchanger
WARNING!Contact with hydraulic oil, cleaning agents or other toxic materialscould cause injury to the skin, the eyes and the respiratory tracts.
Avoid direct skin contact with hydraulic oil or toxic materials, alwayswear protective clothing (gloves, boots, face visor etc.)
If contact with skin or eyes occurs, thoroughly clean skin and rinseeyes with copious quantities of water and then contact a doctor withoutdelay.
DANGER!Failure to observe the necessary safety directives when working on thehydraulic system can lead to serious even fatal injuries.
When working on the hydraulic system all measures related to safetyand environment stated in Chapter 9.3.1 and Chapter 9.3.2 must beobserved!
The machine automatically shuts down when oil temperature is too high.
In this case the water supply to the plate heat exchanger should be checkedfirst.
If it is faultless the heater exchanger may have to be replaced (possiblecalcification).
NoteFor plate heat exchanger operation observe the information inChapter 10.1.
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Procedure:
Fig. 177: Plate heat exchanger
1 Retaining screws2 Plate heat exchanger3 Oil supply4 Cooling water drainage5 Oil drainage6 Cooling water supply
• Open mould to mould opening width
• Switch off motors (key "Motors off")
• Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Check pressure gauge M3 (see Fig. 176, Pos. 2) if system is pressureless
• Shutting off cooling water supply; blow water out of cooling channels
• Remove cooling water hoses (4 and 6) and hydraulic hoses (3 and 5) from plate heat exchanger (2) and tie up, so that oil does not run out
• Remove 4 retaining screws (1) and replace heat exchanger
• Install new heat exchanger in reverse order
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3
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9.4 Working on the pressure accumulator plant
9.4.1 General information on the accumulator system
• Accumulator;Content: Nitrogen (N2), Class 4.0 > 99.99 Vol %
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2
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• Accumulator connecting block
– Discharge valve V4– Safety valves DV5 (responding pressure is set to 211bar and must not
be altered; the valves are tested by the German safety standardsauthority TÜV and sealed)
– Electrically actuated drain valve Y9019; at "Motor off" and"Emergency-off" the accumulator system is automatically drained viathis valve
• Pressure guage M3
• Filling and testing device (option)
Operating pressures
Tab. 6: Operating pressures for accumulator system
NoteThe specified pressure values are so designed that normal temperature fluctuations (e.g. oil and environment) do not adversely affect the function of the accumulator system.
Temperature changes produce changes in gas pressure:
Each 5°C increase or fall in gas temperature increases or reduces gaspressure by 2bar.
Therefore, setting and calibrating must only be done at an operatingtemperature of 45°C.
Function
• Adjustment of extreme fluctuations in flow volume requirement
• Energy accumulation for saving pump drive performance
• All linear machine movements are activated via the accumulator unit
Description Symbol Operating pressure
Gas fill pressure at 20°C N2 130bar
Gas fill pressure at 45°C N2 140bar
Pump actuating pressure .1-B3 180bar
Pump switch off pressure .1-B3 195bar
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9.4.2 Work on the accumulator
WARNING!Improper and incompetent execution of maintenance and repair workcan lead to serious injuries and material damage.
Maintenance and repair work must only be carried out by trained andqualified personnel.
Additional instructions to be observed:
• Maintenance specifications of the manufacturer must be observed and only original replacement parts must be used.
• Accumulator vessels must not be soldered welded nor machined.
• Safety valve DV5 is sealed by the German safety standards authority (TÜV); the seals must not be removed and the setting must not be altered.
• Each time maintenance and repair work is carried out on the hydraulic system the accumulators must be relieved on the oil side by - switching the motor off and - opening discharge valve V4
Check nitrogen pressure with filling and testing device
Procedure • Switch off motors (key "Motors off")
• Slowly open discharge valve V4 (to ensure that accumulator unit is relieved on the oil side)
• Screw the spindle of the filling and testing device out anti-clockwise up to the limit stop
• Close bleeder valve – turn clockwise (depending on type of device)
• Remove protective cap from accumulator and cap nut at the gas valve
• Screw the filling and testing device (option) onto the accumulator
• Turn the spindle of the filling and testing device in and read nitrogen pressure at the pressure gauge (a non-return valve on the filling and testing device prevents nitrogen from escaping through the supply fitting).
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Removing the filling and testing device
• Screw out the spindle of the filling and testing device anti-clockwise up to the limit stop
• Slowly open bleeder valve – turn anti-clockwise (depending on type of device)
• Remove the filling and testing device from the accumulator
• Install gas valve and protective cap to accumulator
• Repeat process on each accumulator
• Close discharge valve V4
Fig. 179: Measuring nitrogen pressure, example
1 Accumulator connecting block2 Discharge valve V43 Accumulator shut-off lever 4 Pressure guage M35 Protective cap6 Pressure gauge of the filling and testing device7 Nitrogen supply connection8 Spindle of the filling and testing device9 Bleeder valve10 Filling and testing device (example)11 Nitrogen accumulator
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5
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Checking nitrogen pressure without filling and testing device
While slowly discharging via discharge valve V4 the pressure last displayedcorresponds to the existing nitrogen pressure, before the needle on thepressure gauge (M3) abruptly returns to zero.
Checking for leakage
If there is a pressure loss in the accumulator, check for leakage by paintingthe safety cap with soap solution. Leakages must be corrected immediately,e. g. by replacing the cap nut and the gas valve insert.
Use only original replacement parts!
Filling accumulator
DANGER!Danger of explosion if gas other than nitrogen is used!
Only dry nitrogen with a purity degree of 99.99% must be used.
Required are:
– Full nitrogen transport bottles (Class 4.0 > 99.99 Vol %)– Filling and testing device (option)
Procedure:
• Switch off motors (key "Motors off")
• Slowly open discharge valve V4 to ensure that the accumulators are relieved on the oil side (see Fig. 179)
• Screw out the spindle of the filling and testing device anti-clockwise up to the limit stop
• Close bleeder valve on the filling and testing device – turn clockwise (depending on type of device)
• Remove protective cap from accumulator and cap nut at the gas valve
• Screw the filling and testing device onto the accumulator
ATTENTION!Gas valve can freeze and sustain damage if filling process is too fast
Open shut-off valve on the supply bottle only slightly so that thenitrogen can flow slowly into the accumulator.
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• Connect the nitrogen transport bottle to the filling and testing device
• Turn the spindle of the filling and testing device in and read nitrogen pressure at the pressure gauge
• Close the shut-off valve on the nitrogen supply bottle at certain intervals and check the pressure on the gauge.
• Continue process until the specified pressure is reached (see Tab. 6: "Operating pressures for accumulator system")
• Nitrogen overpressure can be reduced by opening the bleeder valve on the device provided
NoteSince the nitrogen pressure alters with changes in the gas temperature the required pressure must be finely tuned after temperature has equalized, if required (approx. 2 minutes).
Removing the filling and testing device
• Close shut-off valve on the nitrogen supply bottle
• Screw the spindle of the filling and testing device out anti-clockwise up to the limit stop
• Slowly open bleeder valve – turn anti-clockwise (depending on type of device)
• Disconnect the nitrogen supply bottle from the filling and testing device
• Remove the filling and testing device from the accumulator
• Install gas valve and protective cap to accumulator
9.4.3 Testing of accumulator plant by safety standards authority
Initial acceptance test
The initial acceptance test of the installed accumulator plant is carried outaccording to §9 of the German pressure vessel ordinance by an expert fromthe responsible safety authority (TÜV) in our factory and is certified by meansof a test report (see test book).
Testing before start-up
The acceptance test before start-up at the current location is abolishedaccording to § 9 (4) of the pressure vessel ordinance. The responsible safetyauthority (in Germany) must be notified that the installation was duly carriedout at the operating location.
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Regular tests
The scope of the certification and supervision is regulated by:
• EG Guideline 97/23/EG (pressure system guidelines)
The guideline applies to the design, manufacture and conformity evaluationof pressure systems and units with a maximum permissible pressure of over0.5 bar.
After regulatory initial commissioning, the responsibility for care, maintenanceand application for acceptance testing by the authority, as well as furtherrepeat tests lies with the operating company.
NoteNon-observance of these regulations which could leads to accidents can have legal consequences!
A subsequent replacement of system components which are subject toacceptance, e. g. pressure vessel, must be reported to the relevant safetyauthority (in Germany TÜA or TÜV).
NoteOutside of Germany the acceptance test and supervision is carried out by comparable institutions.
Pressure system guideline 97/23/EG:With the introduction of the pressure systems guideline 97/23/EG (of 29/5/97), only pressure systems which conform to the requirements of the pressure systems guidelines (DGR) can be brought into service throughout the European community after 29/5/2002.
This applies to all manufacturers of pressure systems. The DGR controls the design, the manufacture and conformity evaluation of pressure systems/assemblies.
Operation and continuous inspection will continue to be regulated nationally and is not part of this guideline. In Germany pressure systems are subject to the requirements of the pressure systems ordinance of 21/4/1989, last amended on 23/6/1999, and article 331 of the ordinance of 29/10/2001 (BGBI.IS 2785).
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Suspension of regular test
Suspension of regular testing can be applied for at the responsible safetyauthority if the machine is temporarily out of action.
Test book
The inspection book is supplied as a separate part of the operating manual.
Please confirm the receipt of the inspection book by means of the formenclosed in the book.
The inspection book is a document and is to be kept safe stored (in Germanyaccording to § 14 of the pressure vessel ordinance).
9.4.4 Checking the nitrogen accumulator
The nitrogen pressure in the accumulators is to be tested for the first timeafter one month.
If no loss of gas is established the second test can be made afterapproximately 3 months. If this test is equally positive, yearly testing can nowbe introduced.
Testing of nitrogen pressure and filling the accumulators are described inChapter 9.4.2 "Work on the accumulator".
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9.5 Safety rules for hydraulic hoses
The safety rules are set out in the German safety regulation ZH 1/74 (issueApril 1988) of the trade association and corresponding DIN standards. Theycontain regulations regarding testing, replacing and storing of hydraulichoses.
ATTENTION!All hoses must be inspected at least once a year by an expert for theirsafe operating condition. In addition, the contact-free routing of allhoses must be inspected at monthly intervals. The external influencesof chemicals, direct sunlight or high oil temperatures can shorten theintervals for inspection and replacement of individual hoses.
Replacement Hoses subject to high pressures must be replaced every six years at thelatest:
– at hydraulic block 1 (clamping unit),– at hydraulic block 2 (injection unit),– at hydraulic block 3 (pumps)– at hydraulic block 5 (ejector)– at the drive unit
Criteria • Hoses must be replaced when the following faults are detected during inspection:
• When outer the cover is damaged (e.g. abrasions, cuts, or cracks), cuts or cracks)
• When outer cover is brittle (cracks in hose material)
• By deformation which does not conform to the natural form of the hose or line, whether in pressurized or pressureless state or when bending, e.g. separation of layers, blistering (see also DIN 20066 section 4)
• Leakages
• When hose fittings are damaged or deformed (reduced sealing ability); minor surface damage is no reason for replacement.
• Hoses creeping out of fitting
• When corrosion of fittings reduces function and strength
• Installation rules were not observed (DIN 20066 section 4)Ordering hydraulichoses
1 Description of type andpart number
1
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9.6 Check list for recurring inspection and maintenance work
The listed work to be performed is just an overview and is described in detailin chapters Chapter 9.7 to Chapter 9.15.
Daily checks (Chapter 9.7)
Short inspection before start of work (Chapter 9.7.1)
Maintenance work weekly and during mould change (Chapter 9.8)
Checking safety devices (Chapter 9.8.1)Checking nozzle alignment (Chapter 9.8.2)Checking feedthroat cooling (Chapter 9.8.3)Checking cooling of electric screw drive (option) (Chapter 9.8.4)Checking hydraulic oil level (Chapter 9.8.5)Checking hydraulic oil temperature (Chapter 9.8.6)Lubricating the rods (Chapter 9.8.7)Checking the bearing of the moving mould clamping platen (Chapter 9.8.8)Greasingguide shoes (only K-TEC 155) (Chapter 9.8.9)Checking grease level of the automatic central lubrication system (Chapter 9.8.10)
Maintenance work monthly or every 200 operating hours (Chapter 9.9)
Cleaning ventilation filter of the electrical cabinet (Chapter 9.9.1)Cleaning the ventilation filter of the IQT control unit (Chapter 9.9.2)Cleaning disk drive (Chapter 9.9.3)Initial oil maintenance measures (Chapter 9.9.4)Replacing tank ventilation filter (Chapter 9.9.5)Checking ventilation of the motors (Chapter 9.9.6)Inspecting pumps (Chapter 9.9.7)Plate heat exchanger cooling effect (Chapter 9.9.8)Checking hydraulic pump for leakages (Chapter 9.9.9)Checking the set values of the cooling water manifold (Chapter 9.9.10)Checking modules and electrical switching elements of the control (Chapter 9.9.11)Checking terminal and plug connections (Chapter 9.9.12)Checking the nitrogen pressure of the accumulator system (only S-version) (Chapter 9.9.13)
Maintenance work quarterly or every 1000 operating hours (Chapter 9.10)
Checking seating of thermocouples on the screw cylinder (Chapter 9.10.1)Retighten retaining screws of the screw (Chapter 9.10.2)Checking the nitrogen pressure of the accumulator system (only S-version) (Chapter 9.10.3)
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Maintenance work yearly or every 5000 operating hours (Chapter 9.11)
Checking system pressures (Chapter 9.11.1)Checking the lead seals on the safety valves (only S-version) (Chapter 9.11.2)Checking hoses and connections (Chapter 9.11.3)Checking machine level (Chapter 9.11.4)Checking linear guides (Chapter 9.11.5)Lubricating linear guides (Chapter 9.11.6)Checking stroke measuring systems, limit switches and cables for proper seating and tighness (Chapter 9.11.7)Checking screw release (Chapter 9.11.8)Cleaning cooling water manifold (Chapter 9.11.9)Motor maintenance according to specifications on motor identification plate (Chapter 9.11.10)Cleaning IQT operator terminal and screen (Chapter 9.11.11)Adjustment according to setting instructions (Chapter 9.11.12)Checking platen parallelism (Chapter 9.11.13)Checking tightness of strain rod nut (Chapter 9.11.14)Checking the nitrogen pressure of the accumulator system (only S-version) (Chapter 9.11.15)
Maintenance work every 7500 operating hours (Chapter 9.12)
Changing the buffer battery of the control (Chapter 9.13.1)Replacing the back-up battery of the IQT control (Chapter 9.13.2)
Maintenance work every 6 years (Chapter 9.14)
Replacing high pressure hose lines (Chapter 9.14.1)Basic motor cleaning (Chapter 9.14.2)
Maintenance work every 10 years (Chapter 9.15)
Testing by the responsible safety authority (Chapter 9.15.1)
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9.7 Daily checks
9.7.1 Short inspection before start of work
WARNING!Leaking oil or other contaminants, loose cables, non-functioning safetydevices etc. can cause serious personal injury, material and machinedamage.
Before switching on the machine you must make a short inspection ofthe machine and its surroundings. The machine is to be checked for any visible external damage, such asleakages, loose cable connections, mechanical damage.
For procedure see Chapter 7.17.2 "Short inspection before start ofwork".
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9.8 Maintenance work weekly and during mould change
9.8.1 Checking safety devices
DANGER!Non-functioning safety devices can lead serious injury even death
All safety devices must be checked after the initial start-up, at regularweekly intervals, as well as after alterations or maintenance.
The following must be observed:
• The checks must be made in the sequence set out.
• At each check the machine must effectively shut off.
• The machine must not be operated if a safety device fails.
• Faulty safety devices must be restored to full working order without delay.
Emergency-off switch
The emergency-off switches are to be checked according to Chapter 6.3.1.
Safety switches on safety gates
The safety switches on all safety gates are to be checked according toChapter 6.3.2.
Nozzle guard safety switch
The safety switches on all safety gates are to be checked according toChapter 6.3.3.
Jam bar
The jam bar is to be checked according to Chapter 6.3.5.
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9.8.2 Checking nozzle alignment
WARNING!Damaged or non-matching nozzles can allow material to escape underhigh pressure during operation and cause serious burning or damageto the mould!
• After installing the mould check if the nozzle and the sprue bushing of the mould have matching diameters.
• Check at weekly intervals if nozzle and the sprue bushing of the mould are undamaged correctly aligned.
Select screen page 30.0 and check the temperature display for the feedthroatif the ACTUAL value lies under the REQUIRED value and that tolerancevalues are maintained.
The right temperature and the tolerance values depend on the type anddryness of the material.
NoteThe temperature in the feedthroat must not exceed 80°C.
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9.8.4 Checking cooling of electric screw drive (option)
NoteThe electric screw drive can be supplied as an option. This meansthat the standard extruder motor can be replaced by an electric motor if the customer so desires.
Fig. 181: Electric screw drive
1 Electro motor and planetary drive2 Cooling unit on the frequency converter
NoteThe screw drive motor and the transmission together with the frequency converter are water-cooled.
From a water temperature of 58°C the frequency converter sends a preliminary alarm message. At 60°C the plasticizing drive is shut off and the message "Plasticizing drive not operational" is displayed.
1
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9.8.5 Checking hydraulic oil level
Fig. 182: Display of the hydraulic oil level on the tank
1 Oil level sight glass
WARNING!Non-observance of safety measures during work on the hydraulicsystem and in handling hydraulic oil can lead to serious injuries anddamage to machine and environment.
The directions for work on the hydraulic system and for handlinghydraulic oil must be adhered to, see Chapter 9.3 "Working on thehydraulic system"!
Carrying out visual checks: • Checking oil level at the sight glass (see Fig. 120)
• If necessary top up to approximately 2 cm under the upper edge of the sight glass
NoteIn addition, the oil level is monitored electronically and the machine is switched off when oil level falls below the minimum.
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9.8.6 Checking hydraulic oil temperature
Fig. 183: Temperature display
The oil temperature is monitored by a temperature sensor and is displayed inthe blue and white status information line on every screen page.
• The working temperature for the oil should remain in the 38°C to 50°C range
• At an oil temperature of 55°C a warning is displayed at the IQT control unit.
• At 60°C working movement becomes impossible.
• If the oil temperature reaches 65°C the motor switches off
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9.8.7 Lubricating the rods
Carrying out visual checks: • Check grease film on rods
• If necessary, press grease (Chapter 10.3.2 "Lubrication of the strain rods and guide rods") into the grease nipples with a grease gun until grease comes out at the sides
9.8.8 Checking the bearing of the moving mould clamping platen
Fig. 184: Bearings of the moving mould clamping platen
Carrying out visual checks: • Carry out visual inspection of guide rails for damage and contamination
1 2
3
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9.8.9 Greasing guide shoes (only K-TEC 155)
Procedure: • With a grease gun, press grease (see Chapter 10.3.5 "Greasing the mould clamping platen guide shoes (only for K-TEC 155)") into the grease nipples of the guide shoes, while warm, until grease comes out at the sides
• Operate guide shoes several times without load for at least four lengths of the guides during greasing and add grease if necessary
NoteGreasing several times with smaller quantities is better than adding grease once at the lubricating interval.
9.8.10 Checking grease level of the automatic central lubrication system
NoteThe central lubricating system can be supplied as an option if customer so desires.
Carrying out visual checks: • Checking grease level in reservoir
• Top up if required
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9.9 Maintenance work monthly or every 200 operating hours
9.9.1 Cleaning ventilation filter of the electrical cabinet
Fig. 185: Electrical cabinet, ventilation covers
1 Ventilation covers
Procedure: • Remove ventilation covers (1) by pulling forward
• Remove filter mats if dirty and clean with air pressure or replace if necessary
NoteIn the case of electric screw drive the filter elements of the electrical cabinet of the screw drive are also to be cleaned or replaced if necessary!
1
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9.9.2 Cleaning the ventilation filter of the IQT control unit
Fig. 186: Ventilation of the IQT control unit
1 Ventilation cover2 Clamping lever
Procedure: • Loosen clamping lever (2) and swivel IQT-unit to the left
• Pull off ventilation cover (1) on the rear of the IQT control
• Remove filter mats if dirty and clean with air pressure or replace if necessary
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9.9.3 Cleaning disk drive
• Preparing cleaning disk
• Insert cleaning disk into disk drive
Fig. 187: Operation mode selector switch and key switch
1 Operation mode "Setting"2 Key switch position "2"
Procedure: • Set operation mode selector switch in position "Setting"
• Put key switch in position "2"
Fig. 188: Screen page 10
1
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Procedure: • Select screen page 10
• Enter value 2 in line 10.06
• Actuate "ENTER" key
The message "Writing file" is displayed and the magnetic head is being cleaned;When message erases, the cleaning process is finished.
• Remove cleaning disk
9.9.4 Initial oil maintenance measures
The first oil maintenance measure should take place at the latest after200 operating hours, (see Chapter 9.3.5 "Oil maintenance procedure").
9.9.5 Replacing tank ventilation filter
Fig. 189: Ventilation filter (main and re-suction tanks)
1 Main tank2 Re-suction tank3 Cover4 Housing5 Filter element
1
5
2
4
3
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The ventilation filters are installed on the main tank and re-suction tank.
To guarantee proper ventilation of the main and re-suction tanks, the filtersmust be regularly inspected and replaced when contaminated.
Procedure: • Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Unscrew covers from the housings
• Exchange filter elements
• Refit the cover
Ventilation filter (type and filter insert) for main and re-suction tanks.
K-TEC 40 - K-TEC 60 K-TEC 85 - K-TEC 155
Main tankType Mahle Pi0121 Sm-L
Part No.: 0123548Mahle Pi0121 Sm-LPart No.: 0123548
Filter element 852519 Sm-L (3µ) Part No.: 0118752
852519 Sm-L (3µ) Part No.: 0118752
Re-suction tankType
Mahle Pi0121Sm-LPart No.: 0123548
Mahle Pi0153-T Mic Part No.: 0008189
Filter element 852519 Sm-L (3µ) Part No.: 0118752
852516 Mic Part No.: 0008346
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9.9.6 Checking ventilation of the motors
Fig. 190: Ventilation of electric motors
1 Ventilation grate motor of drive unit2 Ventilation grate electric pump (only K-TEC155 custom design)
Procedure: • Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Remove the rear side cover on the operator side
ATTENTION!Whirled up dirt particles could enter the machine and impair itsfunction.
Do not use air pressure to clean the motor.
Carrying out visual checks: • Check the ventilation grate and the cooling air vents of the motor for contamination and vacuum off if necessary
• Reinstall all covers
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9.9.7 Inspecting pumps
Fig. 191: Pumps
1 Drive unit2 Electric pump (only K-TEC 155 custom design)
Procedure: • Check pumps for unusual noises and for leakages
• In case of excessive noise and/or leakage, repair or replace pump.
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9.9.8 Plate heat exchanger cooling effect
A constant oil temperature of approx. 45°C must be adhered to for safeproduction as well as for the operational safety of Ferromatik Milacroninjection moulding machines. This requires flawless functioning of the plateheat exchanger.
Reduction in cooling performance of the plate heat exchanger becomesevident in excessive cooling water consumption and increased oiltemperature. The cause is deposits in the plates of the oil cooler.
Cleaning can restore the original cooling performance. If cleaning is notpossible, the plate heat exchanger must be replaced.
Further information:
• see Chapter 10.1 "Instructions on the operation of the plate heat exchanger"
• see Chapter 9.3.6 "Changing plate heat exchanger"
9.9.9 Checking hydraulic pump for leakages
Carrying out visual checks: • Visually check all hydraulic hoses, hose connections, cylinders, valves and fittings for damage or leakage
• If damages, such leakage, corrosion, abrasions, cracks, brittleness, deformation etc. are found, the damaged part must be replaced
Further information:
• see Chapter 9.5 "Safety rules for hydraulic hoses"
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9.9.10 Checking the set values of the cooling water manifold
The optimum setting values for the cooling water flow are determined duringmachine operation and are to be set on the flow regulator.
1
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9.9.11 Checking modules and electrical switching elements of the control
WARNING!Improper and unauthorized execution of maintenance and repair work,especially on electric and hydraulic equipment, can lead to seriousinjuries and material damage.
Only electrically qualified personnel must perform work on theelectrical equipment.
DANGER!Danger from electric shock
The supply side of the main switch in the switch cabinet remains liveeven when the main switch is switched off.
Utmost care is to be taken when performing work on or near the mainswitch!
Procedure: • Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Open switch cabinet
• Check that control modules, switch elements and terminals are seated correctly and if necessary reseat properly or tighten screws (see also Chapter 9.9.12 "Checking terminal and plug connections")
• Check plug connections of proportional valves, diverter valves, stroke measuring systems and pressure sensors for correct seating
• Close switch cabinet
9.9.12 Checking terminal and plug connections
DANGER!Danger of electric shock when touching!
The supply side of the main switch in the switch cabinet remains liveeven when the main switch is switched off.
Utmost care is to be used when performing work on or near the mainswitch!
Procedure: • Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Check by hand or with a screw driver if the electrical terminal and plug connections of the switch cabinets, the valves, the sensors etc. are in a flawless condition and seated properly
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9.9.13 Checking the nitrogen pressure of the accumulator system (only S-version)
The nitrogen pressure in all bottles must be tested for the first time after onemonth (see Chapter 9.4.4 "Checking the nitrogen accumulator").
To measure the nitrogen pressure and fill the accumulators follow theprocedure described in Chapter 9.4.2 "Work on the accumulator"
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9.10 Maintenance work quarterly or every 1000 operating hours
9.10.1 Checking seating of thermocouples on the screw cylinder
WARNING!Danger of burning through very high temperatures in the screw cylinderarea!
Always wear suitable protective clothing when working on the injectionunit or its components; this especially includes heat resisting glovesand suitable safety glasses etc.
Fig. 193: Thermocouple
1 Bayonet catch
The thermocouples are set in a cold state into their guides in the injectioncylinder with settable spring tension and fixed with a bayonet catch (seeFig. 193).
The sensors are to be checked for correct seating especially after the heaterbands have been replaced on the screw cylinder.
Fig. 194: Seating of temperature sensor
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Procedure: • Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Remove the screw cylinder cover retaining screws and remove cover
• Pull gently on the cables of the thermocouples and check if the thermocouples are pressed completely back into the guides by the spring when the cable is released
• If necessary increase the spring tension by loosening the bayonet catch and turning the bayonet, set thermocouple back into guide and check seating again
• Install screw cylinder cover and secure with retaining screws
9.10.2 Retighten retaining screws of the screw
Procedure: • Switch machine off at main switch and secure it against being switched on (see Fig. 161)
• Retighten retaining screws (Fig. 171, Pos. 2) of the flange halves (Fig. 171, Pos. 1) with corresponding torque value (see Chapter 10.2 "Torque values")
9.10.3 Checking the nitrogen pressure of the accumulator system (only S-version)
The nitrogen pressure is to be checked for the second time on all bottles (seeChapter 9.4.4 "Checking the nitrogen accumulator").
To measure the nitrogen pressure and fill the accumulators follow theprocedure described in Chapter 9.4.2 "Work on the accumulator".
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9.11 Maintenance work yearly or every 5000 operating hours
9.11.1 Checking system pressures
Testing of system pressures is performed in accordance with the alignmentand setting instructions (service manual) and should be carried out by acustomer service technician.
9.11.2 Checking the lead seals on the safety valves (only S-version)
Fig. 195: Connecting block
1 Safety valve2 Hand wheel with lead seal
• Accumulator connecting block: Safety valves DV5 and DV5.1 are set on 211 bar.
• The setting of valves DV5 and DV5.1 must not be altered. The valves are tested by the standards authority and fitted with lead seals.
NoteThe lead seals must not be removed and the settings must not be altered.
1
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9.11.3 Checking hoses and connections
Fig. 196: Hoses, example injection cylinder (selection)
Carrying out visual checks: • Check all hoses and fittings for leakages and damage (abrasions)
• Re-tighten fittings if necessary. Observe torque values (see Chapter 10.2.2 "Torque values for Bosch hydraulic components")
Further information:
• 9.5 "Safety rules for hydraulic hoses"
9.11.4 Checking machine level
For proper machine operation it is absolutely necessary to level the machineprecisely along and across its axes.
Clamping and injection unit alignment mustbe checked at least once a year orevery 5000 operating hours and re-aligned if necessary.
Further information: Chapter 5.3 "Aligning the machine"
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9.11.5 Checking linear guides
Fig. 197: Injection unit linear guides
1 Grease nipple
Carrying out visual checks: • Visually check injection unit linear guides for damage
9.11.6 Lubricating linear guides
Procedure: • With a grease gun, press grease (see Chapter 10.3.4 "Lubrication of linear guides of injection unit") into the grease nipples of the injection unit linear guides, while they are still warm, until grease comes out at the sides (two grease nipples each at front and rear)
• As an option, the linear guides can be fitted with long-term grease depots. These depots are to be exchanged or filled with new grease. Filling is done via the face side opening with grease cartridges.
1
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9.11.7 Checking stroke measuring systems, limit switches and cables for proper seating and tighness
Fig. 198: Stroke measuring systems
1 Stroke measuring system for ejector2 Stroke measuring system for moving mould platen3 Stroke measuring system for screw movement
NoteChecking the stroke measuring system must be done by two persons.
2
1
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Procedure: • Set operation mode selector switch on "Setting"
• Tighten the retaining screws of the stroke measuring system to correct torque values (see Chapter 10.2 "Torque values")
• 1. person manually checks the stroke measuring system for correct seating (tries shaking)
• 2. person observes the status display on the screen for each respective stroke measuring system
• The stroke values displayed on screen must not change during the check.
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9.11.8 Checking screw release
Fig. 199: Screen page 30
Procedure: • Switch on machine at main switch (operating system starts)
• On screen page 30.0 set required temperature on 200°C
• Actuate key "Cylinder heating on"
• Wait until screw cylinder is heated and the message "Screw release missing" erases
• On screen page 30.0 set wide tolerance band lower than 30°C
• Raise required temperature on screen page 30.0 by 30°C (the fault message "screw release missing" appears")
• Press key "Plasticizing"
If the screw starts to turn, screw release is defective. Have the fault fixed
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9.11.9 Cleaning cooling water manifold
Fig. 200: Cooling water manifolds
1 Locking screw2 Sight glass3 Duct cleaning brush
Cleaning and maintenance work should be done at regular intervals. Thesedepend on the contaminated state of the cooling medium
Procedure: • Shutting off cooling water supply
• Drain cooling water into suitable container
• Open upper locking screw (1)
• Clean sight glass (2) with a duct cleaning brush (3) (or pull out sight glass upwards)
• Replace the locking screw O-ring
• Replace O-rings at the sight glass and reinstall sight glass
• Lock locking screw
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9.11.10 Motor maintenance according to specifications on motor identification plate
Fig. 201: Motor maintenance
1 Identification plate2 Motor grease nipple, example
The maintenance intervals and the lubricating medium must comply with thespecification on the identification plate.
Further information: Basic motor cleaning (Chapter 9.14.2)
9.11.11 Cleaning IQT operator terminal and screen
• Wipe IQT control unit and screen clean with a moist but not wet cloth (use a special screen cleaner if required).
9.11.12 Adjustment according to setting instructions
NoteThe machine parameters, according to adjustment and setting instructions, are to be checked and if necessary corrected by a customer service technician.
9.11.13 Checking platen parallelism
Further information: Checking mould clamping platen parallelism(Chapter 5.3.5)
2
1
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9.11.14 Checking tightness of strain rod nut
Further information: Mould installation with strain rod positioning(Chapter 7.2.2)
9.11.15 Checking the nitrogen pressure of the accumulator system (only S-version)
The nitrogen pressure is to be checked on all bottles (see Chapter 9.4.4"Checking the nitrogen accumulator").
To measure the nitrogen pressure and fill the accumulators follow theprocedure described in Chapter 9.4.2 "Work on the accumulator"
WARNING!Contact with hydraulic oil, cleaning agents or other toxic materialscould cause injury to the skin, the eyes and the respiratory tracts.
Avoid direct skin contact with hydraulic oil or toxic materials, alwayswear protective clothing (gloves, boots, face visor etc.)
If contact with skin or eyes occurs, thoroughly clean skin and rinseeyes with copious quantities of water and then contact a doctor withoutdelay.
DANGER!Failure to observe the necessary safety directives when working on thehydraulic system can lead to serious or even fatal injuries.
When working on the hydraulic system all measures related to safetyand environmental protection stated in Chapter 9.3 "Working on thehydraulic system" must be observed!
ATTENTION!Operating the drive unit with an oil empty tank leads to serious pumpdamage!
The drive unit must always be operated with oil.
The maintenance work of changing the oil, cleaning the tank, testing thefunction of the oil level monitor and replacing the ventilation filter is carriedout in one operation.
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Draining oil and checking function of oil level monitor
• Remove cube plug from oil level monitor (3);the message "Oil level too low" must appear on the screen
• Actuate key "Motor on";the motor should not switch on
• Should the motor start nevertheless, there is a defect present which must be corrected without delay.
• Replace cube plug on the oil level monitor
• Unscrew the cover from the oil filler opening
• Drain oil with a suitable device until the float in the sight glass (4) reaches the lower end of the display
• Stop oil drainage
• The message "Oil level too low" must appear on the screen
2
1
4
3
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• Actuate key "Motor on"
• The motor should not switch on
• If the motor does start, the oil level monitor must be replaced
• Drain tank of oil completely
Cleaning main and re-suction tanks
ENVIRONMENTALLY DANGEROUS!Remove oil spots from the machine and the floor thoroughly anddispose of oil soaked rags and containers immediately and properly,(see Chapter 9.3.2 "Storing and disposing of hydraulic oil")!
Fig. 203: Cleaning ports
1 Tank cover re-suction tank2 Tank cover main tank
Procedure: • Drain oil from the re-suction tank
• Drain oil from main tank
• Remove tank cover
1
2
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• Loosen the hexagon head screws from the circumference of the suction filter
• Pull off suction filter from the retaining flange
• Wash out suction filter with suitable cleaning agent (cleaning solvent, petroleum)
• Blow out suction filter with air from inside to out
• Visual check! If damaged replace suction filter
NoteOil filters are hazardous waste and must be disposed as such!
• Slide suction filter centrically over retaining flange and secure with hexagon bolts
• Remove remaining oil with an industrial suction device or a non-fibrous cloth
• Clean tank with flushing oil; flushing oil and hydraulic oil must be compatible
• Clean out sludge and solid remains from tank
• Replace tank cover seals
• Screw on tank cover
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Replacing tank ventilation filter
see "Replacing tank ventilation filter" on page 62
Replacing oil filter
see "Change of oil filter" on page 33
Pour in hydraulic oil
• Fill main and re-suction tanks with hydraulic oil through a 5µ-filter (see Chapter 5.4.3 "Filling with hydraulic oil")
NoteThe pump housing should be bled to avoid pump damage
Bleeding the pump housing
Fig. 204: Hydraulic pump
1 Oil leakage connection
Procedure: • Remove upper oil leakage connection of the pump
• Fill housing with hydraulic oil until oil emerges
• Reinstall leakage oil connection
1
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Concluding work
• Check oil level in sight glass and top up if necessary until the oil level is approximately 2 cm under the upper edge of the sight glass
• Screw on the lid of the oil filler opening (for torque values see Chapter 10.2.4 "Torque value for tank cover nuts")
• Allow pump to run 30 minutes in neutral while fitting a 1µ bypass filter; this filter is then to be replaced by a 3µ bypass filter when the message "Oil filter contaminated" is displayed (see "Change of oil filter" on page 33)
• After every oil change allow the machine to make a number of movements to bleed the hydraulic system of air
• Bleed the injection, ejector and traverse cylinders (see Chapter 6.4.1 "Bleeding the hydraulic system")
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9.13 Maintenance work every 3 years
9.13.1 Changing the buffer battery of the control
Fig. 205: Back-up battery, example
1 Power supply module2 Cover plate for removing battery3 Removal instructions
For saving the control IO data there is a back-up battery behind the powersupply module in the rear wall module of the electrical cabinet.
Replace the backup battery every three years.
Instructions for battery removal can be found on the inside of the rear wall ofthe electrical cabinet directly under the power supply module.
2
1
3
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9.13.2 Replacing the back-up battery of the IQT control
To avoid data loss during power failure or when switching the machine offthere is a lithium battery installed in the IQT control unit. Since the service lifeof the battery depends on many factors it is recommended to replace it atyearly intervals. The battery should be visually checked at regular intervals(danger of battery leakage!). As soon as the battery is empty required valuesare no longer displayed on screen.
NoteThe battery change in the Provit controller on the rear side of the IQT control unit should be made while machine is switched on.
Procedure: • Set operation mode selector switch in position "Setting"
• Remove rear cover plate from the IQT control unit
• Remove lithium battery from the battery compartment of the Provit controller
• Insert new battery (watch polarity!)
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9.14 Maintenance work every 6 years
9.14.1 Replacing high pressure hose lines
It is recommended to replace all high pressure hose lines on the machine.Contact Ferromatik Milacron customer service (see Chapter 9.16 "Customerservice").
9.14.2 Basic motor cleaning
Motor maintenance includes:
• Lubricating the bearings
• Basic motor cleaning
General motor maintenance is minimal It is sufficient, depending on degree ofcontamination, to clean the cooling air ducts with dry, oil-free air compressedair. In addition, it is important not to displace the air ducts for the air intakeand exhaust.
Adding grease: Take note that the lubricity is greatly reduced when mixing greases of varioustypes.
Before switching to another grease type (soap based), thoroughly clean thebearings and lubricating pipes.
Grease is added with a grease gun. The identification plate of the motor listsgreasing interval, quantity and grease type. Grease should be added duringoperation so that the fresh grease spreads throughout the bearing.
General cleaning: General cleaning should be carried out, depending on degree ofcontamination, at the latest after 20.000 operating hours. For this, the motoris stripped down and the windings and bearings are cleaned (see parts list).
NoteThe winding and insulation system corresponds to the latest technical know-how and is subject to constant quality control. However, should repairs become necessary it is absolutely essential to maintain the dimensions and the design of the original windings. This applies especially to the air insulation of the end windings.
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9.15 Maintenance work every 10 years
9.15.1 Testing by the responsible safety authority
The commissioning of the injection moulding machine with pressureaccumulator plant must be reported in time to the responsible safetystandards authority. The necessary form is included in the inspection book.
The safety standards authority will then carry out regular tests according tothe time interval prescribed by the pressure vessel ordinance (as a rule after10 years) (see Chapter 9.4.3 "Testing of accumulator plant by safetystandards authority").
9.16 Customer service
Ferromatik Milacron customer service can be reached under the followingtelephone numbers:
Note When repositioning the strain rods the distance between platens changes by min./max. 200 or 400 mm.All measurements in mm.Right of alterations in design and construction reserved.
*Option: Reinforced mould clamping platens at standard LHW (distance between strain rods)** Standard: Nozzle body/nozzle tip (other design on request)
Machine type K-TEC 40 K-TEC 60 K-TEC 85Tie bar frame:LHW 320 x 320 355 x 355 420 x 420
Note When repositioning the strain rods the distance between platens changes by min./max. 200 or 400 mm.All measurements in mm.Right of alterations in design and construction reserved.
*Option: Reinforced mould clamping platens at standard LHW (distance between strain rods)** Standard: Nozzle body/nozzle tip (other design on request)
Machine type K-TEC 110 K-TEC 155Tie bar frame:LHW 470 x 470 500 x 500 560 x 560
* +20 mm adjustable1) Distance between strain rods2) Injection unit (international size)
NoteWhen repositioning the strain rods the distance between platens changes by min./max. 200 or 400mm. All measurements in mm.Right of alterations in design and construction reserved.
10.1 Instructions on the operation of the plate heat exchanger
10.1.1 Construction and function
Fig. 208: Plate heat exchanger
The welded platen heat exchanger is made up of non-profiled interleavedstainless steel plates (1.4401). The flow compartments contain stainless steelturbulence baffles which, in a vacuum process with copper (99.9%) havebeen soldered into a compact and pressure-resistant unit.
10.1.2 Start up procedure
Prior to start up ensure that the admissible values for pressure andtemperature as shown on the performance plate are not exceeded. Ensurethat the connecting lines are firmly tightened.
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10.1.3 Notes on cooling water
Water channels must not sustain damage through corrosion or becomeclogged by means of organic or inorganic substances. Corrosion causesleakages on hose fittings, while deposits impede heat transfer to the water orclog the channels.
Contamination
NoteRegulations regarding water contents must be observed and adhered to (see Chapter "Deposits").
Filters (max. 0.8 mm mesh width) are to be provided when contaminatedmediums such as surface water or circulating cooling water (opencirculation); heater water (esp. old plants) or similar, are in use.
Further, with these mediums the greatest possible volume flows are to bemoved. A scant volume flow or partial load may lessen the turbulence in theheat exchanger and increase the risk of contamination. If a build-up ofdeposits in the flow spaces is expected because of the quality of the medium(strong contamination; high degree of water hardness etc.), cleaning is to becarried out at regular intervals.
Corrosion
Galvanic corrosion Galvanic corrosion is caused when differing precious metals have metal tometal contact or are in contact with an electrolyte. This causes the non-precious metal to pass ions into the fluid, i.e. the metal is attacked bycorrosion. This can be avoided by avoiding metal to metal contact.
Biological corrosion Biological corrosion is caused through various bacteria which triggeroxidation on the metal surfaces. This is to be avoided through proper watertreatment by means of antibacterial additives. Additionally, a turbulent waterflow appreciably reduces the growth of such bacteria or algae.
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Deposits
The water must be treated to avoid deposits of organic or inorganicsubstances. This means freeing the water from certain ingredients orreducing their concentration to a non-critical level.
The problems are associated mainly with carbonate and phosphate, to alesser degree with sulphates and silicates. The deposits of calcium-carbonate are a consequence of carbonate hardness in the water.
Tab. 12: Maximum permissible flow rates
Tab. 13: Cooling water quality
Maximum permissible rates of water flow
Aluminium and aluminium alloys 1.8 m/s
Brass/bronze 2.4 m/s
Steel 6.0 m/s
Rubber/plastics 5.0 m/s
Cooling water quality – standard values
Cooling water temperature < 30°C
pH value min. 7.0 max. 8.5
Total hardness min. 0.5 mol/m3
max. 10.0 mol/m3
Carbonate hardness min. 1.0 mol/m3
max. 2.0 mol/m3
Chloride ions max. 200 mg/l
Sulphate ions max. 325 mg/l
Nitrates and nitrites max. 50 mg/l
Ammonia max. 0.5 mg/l
Iron max. 0.2 mg/l
Manganese max. 0.1 mg/l
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Technical data
Setting instructions
Fig. 209: Cooling water manifold
The cooling water flow rate is controlled manually via the correspondingcircuit of the cooling water manifold. A central swimmer position in theviewing glass is recommended. This ensures a turbulent flow and thereby theleast amount of deposit in the cooling channels.
When carbonates and phosphates etc. are present, water which is notadequately treated and a flow rate which has been set too low increases boththe rate of deposit and the follow-up temperature. This does not present aproblem in factory-wide closed cooling water circuits; neither is the re-coolingcapacity increased since heat dissipation remains constant.
Higher flow rates also do not present a problem, as long as the increasedflow rates are supplied by the factory cooling system.
The cooling requirements for flange cooling in comparison to the coolingrequirements for the mould are minimal.
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Cleaning
The necessity of cleaning will be determined by the respective application.Basically, it is to be ensured that no scale and/or other deposits can form onthe platens. Cleaning can only be carried out by flushing; preferably inreverse flow, i.e. against the actual operational flow.
Deposits in the cooling channels can be removed by flushing with a suitablesolution.
The flushing solution deconex 25 ORGANAZID made by Borer Chemie isrecommended. Deconex 25 ORGANAZID is used in a solution of 2 to 5%with distilled water. Higher concentrations can be used in case of strongerdeposits.
Deconex 25 ORGANAZID solution is biodegradable and thereforeenvironmentally friendly. It is based on citric acid and highly compatible withaluminium. Additionally, it is non-foaming. The temperature should be 20°Cor slightly higher. Higher temperature increases flushing effect. Flushing timeshould be approximately 3 – 5 minutes. After flushing with solution rinse foran adequate period with water.
Alternatively, other cleaning agents recommended for stainless steel andcopper by a cleaning agent supplier can be employed. Before using,confirmation from the of the cleaning agent supplier that the intended cleanerwill not attack the fitted materials must be obtained.
ATTENTION!Generally, the respective valid safety regulations and recommendationsof the cleaning agent supplier must be adhered to.
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10.2 Torque values
1 kpm = 9.807 Nm = 7.233 lb./ft = 86.8 lb./in.
1 Nm = 0.102 kpm = 0.7376 lb./ft. = 8.851 lb./in.
10.2.1 Torque values for cylinder screws DIN 912 on Ferromatik Milacron subassemblies
Note on installation: Screws are delivered lightly oiled. When applying the specified torque for tightening, the screws should not be additionally oiled or greased.
The screws supplied have a tensile strength class 12.9
The torque value corresponds to tensile strength class 10.9
Tab. 14: Torque values for subassemblies
Dimension Torque valueM4 4.1 Nm
M5 8.5 Nm
M6 14 Nm
M8 35 Nm
M10 69 Nm
M12 120 Nm
M14 190 Nm
M16 295 Nm
M18 405 Nm
M20 580 Nm
M22 780 Nm
M24 1000 Nm
M27 1500 Nm
M30 2000 Nm
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10.2.2 Torque values for Bosch hydraulic components
Socket head screws DIN 912 of stability class 10.9
Tab. 15: Torque values for Bosch hydraulic components
10.2.3 Torque values of nuts for studs on injection and traverse cylinders
Tab. 16: Torque values of nuts for studs on injection and traverse cylinders
10.2.4 Torque value for tank cover nuts
2.0 Nm
Dimension Torque valueM4 2.0 +0.5 Nm
M5 6.0 +2.0 Nm
M6 11.0 +3.0 Nm
M8 26.0 +5.0 Nm
M10 50.0 +10.0 Nm
M12 90.0 +30.0 Nm
M14 160.0 +20.0 Nm
M16 240.0 +20.0 Nm
M20 450.0 +50.0 Nm
Dimension Torque valueM8 20 Nm
M10 35 Nm
M12 60 Nm
M14 100 Nm
M16 150 Nm
M20 290 Nm
M24 500 Nm
M30 1067 Nm
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Technical data
10.3 Lubricant recommendations
To fully utilize the efficiency of your high-quality injection moulding machine itabsolutely necessary to keep to the planned lubricating intervals and use onlythose high-grade lubricants best suited to your machine. It increases theservice life of the machine. Warranty for the machine is based on the use ofthese or other equivalent lubricants.
10.3.1 Hydraulic oils
HLP 46 with quality-Class ISO VG46 according to DIN 51524/2 andDIN 51519
– ARAL, Vitam GF 46– AVIA, Avilub RSL 46– BP Energol HLP 46– Deutz Oel, HY-S 46– Esso, Nuto H 46– KLÜBER LUBRICATION, LAMORA HLP 46– Mobil, DTE 25; MOBIL DTE Excel 46– Shell, Tellus 46– TEXACO, Rando Oil HD B-46– Unil opal, HFO 46, HYFRO 46– or hydraulic oils of provable equal value
ATTENTION!• Refilling only via 5µ-filter or finer!
• Observe oil level on sight glass
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10.3.2 Lubrication of the strain rods and guide rods
10.3.3 Lubrication of the electric motor
Further information: identification plate on the electric motor
10.3.4 Lubrication of linear guides of injection unit
Lithium-saponified mineral oil based greases with the following basicviscosity must be used:
Mobil Mobilux EP 2 EP-grease lithium soap baseCertification according to DIN 51 502: KP2K-20
Lubricating the strain rods / grease nipple on the moving mould clamping platenLubricating the guide rods of the ejector cross beam* / grease nipple* on the ejector cross beam*Greasing of strain rods via strain rod pressure plate* / grease nipple on pressure plateCentral lubrication system*
RIVOLTA Rivolta G.w.F.compound
Anti-seize and lubricating agent
Seating of strain rods in the stationary mould clamping platen and the end plateStrain rod thread
*) Optional equipment
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Technical data
10.3.5 Greasing the mould clamping platen guide shoes (only for K-TEC 155)
Lithium-saponified mineral oil based greases with a base oil viscosity of ISO-VG100 to ISO-VG 150 must be used. (Examples see Chapter 10.3.4)
10.3.6 Lubrication of the electric screw drive (option)
The planetary drives have life-time lubrication. A high-grade, synthetic gearoil of viscosity class ISO-VG 220 is used for lubrication
Further information: Specification on the identification plate.
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Index
11 Index
AActivate special programme ...........................7-95Air pressure lines
setting .......................................................7-23AIRPRESS gas injection technique (GIT) .....7-192Altering installation height ................................7-6
BBack pressure ................................................7-74Background data set ....................................7-122
compare with foreground data set ...........7-124Basic motor cleaning ......................................9-89Blow-off valve ................................................5-27
bleeding ....................................................6-10Clamping force
setting .......................................................7-17Clamping unit
aligning the base .......................................5-10overview .....................................................4-2setting .......................................................7-15
Closing speeds ..............................................8-10Control adjustment .........................................7-59Control parameter determination ....................7-62Cooling time ...................................................7-78Cooling water connection ...............................5-25Cooling water lines
Cursor control ..............................................7-169Customer service ...........................................9-90Cycle time monitoring ..................................7-103Cylinder heating
Ejector and core movement .........................7-187Ejector platen safety ......................................7-22Ejector settings ..............................................8-10Electric cabinet ................................................5-8Electric motor
checking .....................................................6-4checking rotational direction ........................6-1
Installation with crane ......................................5-9Installing the screw ........................................9-21Intrusion ........................................................7-78
alignment ..................................................5-10cleaning ....................................................5-21filling and connecting ................................5-21installing .....................................................5-2setting .........................................................7-2start up .......................................................6-1
Main switch ......................................................3-5Maintenance ....................................................9-1Maintenance work ..........................................3-18Material or colour change .............................7-156
Monitoringcycle time ............................................... 7-103plasticizing stroke ................................... 7-106plasticizing time ...................................... 7-105
Monitoring ejector rest position ...................... 7-21Monosandwich process ............................... 7-188Motor overload protection ................................ 6-4Motor safety responds ..................................... 8-8Mould
PPage in page function ....................................4-17Parameter sets on disk
storing and reading in ..............................7-125Permissible ambient conditions ........................5-1Pipe connections .............................................6-4Piston rod seals
replacing ...................................................9-27Plasticizing delay ...........................................7-78Plasticizing process
setting .......................................................7-71Plasticizing stroke monitoring .......................7-106Plasticizing time monitoring ..........................7-105Power supply ...................................................4-9Preparation
for delivery of machine ................................5-2transport within the company’s premises .....5-3
RRecording of process data .............................7-99Regulatory application .....................................2-1Repair work ...................................................3-18Repairs ............................................................9-1Repairs and maintenance ................................9-1Required and actual value comparison .........7-171Required value entry ......................................4-18Rotational direction
Screw change ................................................9-18Screw end position control .............................7-75Screw r.p.m. ..................................................7-73Screw release missing .....................................8-6Screw rpm counter .........................................7-74Screw suck-back ...........................................7-75Screw tip
cylinder heating ........................................7-64injection unit .............................................7-64machine monitoring ..................................7-87plasticizing process ...................................7-71the clamping unit ......................................7-15the injection process .................................7-79
Setting process graphics ..............................7-166Shift part
Smart Card Reader ........................................4-28Source of fault
injection process .......................................8-11mould installation ......................................8-10
SPC control chartssetting .....................................................7-179
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Index
Standard graphics ........................................7-117display ....................................................7-120operation modes .....................................7-118setting .....................................................7-117
Start key ..........................................................3-7Start of work
short inspection ......................................7-140Start up procedure ...........................................6-1Statistical process control ............................7-177Step list ...........................................................8-1Switch off the machine .................................7-158Switchover
in the operating manual ..............................1-1on the machine. ...................................1-1, 1-3
Warning symbolsdanger to humans .......................................1-1in the operating manual .......................1-1, 1-2on the machine. ...................................1-1, 1-3
