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Operating Manual

Version: TB4GBV01 05/00

Injection Moulding Machine type PLUS

Machine Type: PLUS 350 / 75

Control Type: UNILOG B2

Machine No.: 25336

Year of manufacture: 2003

Read before using the injection moulding machine andkeep nearby for reference

Battenfeld GmbHScherl 10 • D-58527 Meinerzhagen

Tel. ++49 2354/72-0 • Fax ++49 2354/72-234

Battenfeld Kunststoffmaschinen Ges.m.b.H.Wr.Neustädter Straße 81 • A - 2542 Kottingbrunn

Tel. ++43 2252/404-0 • Fax ++43 2252/404-1062

www.battenfeld.com

DIN EN ISO 9001

Injection Moulding Technology

TB2D

ED1B

-1

Read before using the control unit andkeep nearby for reference

Version: TB4GBV00 9/99

Machine Type: PLUS 350V / 75

Control Type: UNILOG B2

Machine No.: 25556

Year of manufacture: 2003

Operating ManualInjection Moulding Machine type PLUSV

Battenfeld GmbHScherl 10 • D-58527 Meinerzhagen

Tel. ++49 2354/72-0 • Fax ++49 2354/72-234

Battenfeld Kunststoffmaschinen Ges.m.b.H.Wr.Neustädter Straße 81 • A - 2542 Kottingbrunn

Tel. ++43 2252/404-0 • Fax ++43 2252/404-1062

www.battenfeld.com

DIN EN ISO 9001

Injection Moulding Technology

TB2D

ED1B

-2

Index

A:PB2GBI1A.P65B: PB2DEI1A.P65E: 180202 / RuderG: 190202 / G. Krajnik

Section - IN1Page - 1

Chapter 1 General information

Chapter 2 Safety

Chapter 3 Technical Data

Chapter 4 Transport - Installation

Chapter 5 Structure and function

Chapter 6 Comissioning

Chapter 7 Maintenance

Chapter 8 Spares / Plans

Chapter 9 Customer service

Chapter 10 Extra chapter for special modules

?

0

A:PB2GBI1A.P65B: PB2DEI1A.P65E: 180202 / Ruder

G: 190202 / G. Krajnik


Index

Index

A: PB2GBI2A.P65B: PB2DEI2A.P65E: 180202 / RuderG: 190202 / G. Krajnik


1.0 General information1.1 Introduction

1.2 Scope

1.3 Explanation of symbols

1.4 Copyright

1.5 Transfer Certificate

1.6 Declaration of conformity

2.0 Safety2.1 Safety regulations

2.2 Safety gate monitoring

2.3 Pneumatic Safety Gate andSafety Bar

2.4 Safety gate and guard

2.5 Protective equipment robot(option)

2.6 Checking safety devices

2.7 Table for risk assessment

3.0 Technical Data3.1 General information

3.2 Hydraulic equipment

3.3 Electrical equipment

3.4 Water system

3.5 UNIFEED material feeder

3.6 Injection unit

3.7 Clamping unit

3.8 Injection pressure charts

3.9 Injection speed chart

3.10 Injection volume chart

3.11 Screw speed chart

3.12 Clamping force charts

3.13 Clamping speed chart

3.14 Mould dimensions

3.15 Conversion table for shotweights

3.16 Weights of screws and barrels

3.17 Torque settings for barrel endcap fixing bolts

3.18 Torque settings for bolts

3.18 Mould mounting dimensions

3.19 Foundation and installationplan

4.0 Transport - Installation4.1 General information

4.2 Storage

4.3 Unloading

4.4 Space requirement plan

4.5 Transporting the IMM

4.6 Installing the IMM

4.7 Removing preservative agents

4.8 Levelling the IMM

4.9 Hydraulic system

4.10 Water system

4.11 Pneumatic system


4.13 Mould mounting

4.14 Interface


4.16 Test run and interlock test

A: PB2GBI2A.P65B: PB2DEI2A.P65E: 180202 / Ruder



Index

5.0 Structure and function5.1 View of assemblies

5.2 Clamping unit

5.3 Injection unit

5.4 Hydraulics

5.5 Pneumatics

5.6 Electrics

5.7 Control unit

6.0 Comissioning6.1 General information

6.2 Initial commissioning

6.3 Starting the IMM afterEMERGENCY STOP

6.4 Test run without material

6.5 Filling the material hopper

6.6 Test run with material

6.7 Operation

6.8 Shutting the IMM down

6.9 Shut down procedure

6.10 Changing the place ofinstallation

6.11 Disposal

? 7.0 Maintenance7.1 General information

7.2 Transport, storage anddisposal of lubricants

7.3 Disposal of electrical andelectronic components

7.4 Hydraulic oil and lubricant table

7.5 Maintenance chart

7.6 Hydraulic system

7.7 Water system



8.0 Spares/ Plans

9.0 Customer service9.1 General information

General information

A: PB2GB0AB.P65B: PB2DE0AB.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter -1Page - 1

1.0 General information

1.1 Introduction

This machine documentation is written with theintention that it should be read, understood andfollowed by all those who will be responsible forthis Battenfeld injection moulding machine(referered to as IMM hereafter).

The complete documentation should be heldclose to the IMM and be available to operatingand maintenance staff at all times.

Only after reading through thoroughly, especiallySection "Safety",can problems with the IMM beavoided and trouble free operation ensured. It istherefore essential that this operating manual bemade available to the personnel concerned.This should take place before commissioning,because we can take no responsibility fordamage and operating faults arising fromignorance of this operating manual!

There are facilities for the training of youroperating staff in your works or at our factory.For further information, contact the "TrainingDepartment".

Should you still encounter difficulties, pleasecontact our Customer Service Department orour Local Technician or Agent (addresses aregiven in Section "Customer Service") who willbe pleased to help.

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

The presentation and content of this manual aresubject to technical alteration, as required bycontinuous improvements of the IMM and / or itsplant components.

1.2 Scope

IMM of the present series of this range havebeen designed as standard for the processing ofthermoplastics and optionally for processingelastomers and LIM (Liquid Injection Moulding -process for the injection moulding of liquid twopart silicone rubbers).

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

1.3 Explanation of symbols

The Warning symbol is to be found with all worksafety instructions in this operating manualwhere there is a hazard to the health and safetyof persons. Follow these instructions and act inthese cases with extreme care. Pass on all worksafety instructions to other users. In addition tothe instrutions given in this operatingmanual,the general health and safetyregulations for the prevention of accidents mustbe observed.

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Chapter -1Page - 2

General information

These warning and prohibition symbols may bepresent on the IMM. They warn of particulardangers of death or injury to operating andmaintanance personnel

The "Hot surface" sign indicates areas wherethere is a burning hazard. The user must beprotected by appropriate personnel protectiveequipment (PPE) (see DIN EN 407).

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

Surfaces with the "No step" sign must not bestepped on.

CautionCaution marks those sections in this operatingmanual where there are instructions orregulations which must be observed and/or thatthe correct sequence of work should befollowed, and/or that care must be taken toavoid damage to the IMM and associatedequipment.

The high voltage symbol in the manual indicatesthose places where personnel can come intocontact with electrical equipment and materials.Care must be taken to ensure that theapplicable local electrical safety regulations arefollowed.

The symbol for environmental hazard drawsattention to environmental hazards, for instance,concerning the disposal of all sorts of materials.When carrying out repair and maintenance workthe corresponding rules and regulations must beadhered to.

1.4 Copyright

The copyright of this operating manual remainswith Battenfeld GmbH. This operating manual isintended for assembly, operating andsupervisory staff. It contains instructions anddiagrams of a technical nature which may notbe reproduced entirely or in part, distributed orused without authorisation for the purposes ofcompetition or conveyed to third parties.

1.5 Transfer Certificate

The transfer certificate enclosed with thisoperating manual is to confirm the transfer ofthe IMM and the completeness of the operatingmanual. After checking, the transfer certificateshould be completed, signed, and returned tothe "Documentation" department.

1.6 Declaration of conformity

The Declaration of conformity is included at theend of this chapter.

General information

A: PB2GB0AB.P65B: PB2DE0AB.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter -1Page - 3

Telefax message

To: Documentation Dept. BKU ++43/2252 404 - 3002Documentation Dept. BMF ++49/2354 72 - 551

Transfer Certificate

for confirmation of acceptance of technical documentation by the customer

1) Machine type: ______________________________________ Com. no.: _________________

2) Customer’s address ____________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

3) We have acquired the machine detailed in para. 1. On handover of the

were provided with ___________________________________ (number)

Operating manual(s) in the __________________________ language.

_________________________ ___________________________________________Date Customer’s signature

4) Date of transfer: ___________________________________________

5) Address of authorised agent orimporter:

Company stamp / signature

6) The injection moulding machine hasbeen handed over to the customer inaccordance with the manufacturer’sinstructions.

_______________________________ Signature if different from Para. 5Date Service technician’s signature

Safety

A: PB2GB0BB.P65B: PB2DE0BB.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter - 2Page - 1

2.0 Safety

2.1 Safety regulations

General information

Numerous safety devices contribute to safetyand accident prevention on the machine(hereinafter IMM) or robot. The proprietor of themachine is responsible for the proper function ofthe safety devices.

The IMM is designed and built to the currentlyapplicable safety requirements of EuropeanStandard EN 201 and is safe in operation.Hazards can arise from this IMM if it isimproperly used by untrained personnel or isused for purposes for which it is not designed.

For reasons of safety the control software mustnot be changed. Any modification of thesoftware without our consent will invalidateclauses of the warranty!

The environment, safety and accidentprevention regulations, as well as operatingprocedures, are always applicable to therunning of the IMM.

Unauthorised modifications or alterations whichaffect the safety of the IMM are not permitted.

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

Responsibilites and procedures for all workinvolving installation, dismantling, modificationand maintenance of the IMM are to be recordedin a procedure.

Modifications and alterations which affect thesafety of the IMM,as well as all work relating tomaintenance, are to be documented in aninspection record which is to be stored for atleast ten years.

The IMM is designed and built to the currentlyapplicable Standard DIN EN 292-2 so that noiseemission hazards when used properly withoptimised settings are reduced to the lowestattainable level.

Before operating the IMM with a robot, thesafety regulations in the Robot OperatingManual must be followed without fail.

Before operating the IMM with integratedperipheral equipment (e.g. material feeder) thesafety regulations in the appropriate PeripheralEquipment Operating Manual(s) must befollowed without fail.

Connection and installation of peripheralequipment may only be carried out byauthorised personnel.

The top guard over the clamping unit (PLUShorizontal)must remain permanently closed,unless robots have been fitted which conform tothe local safety regulations.

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Chapter -2Page - 2

Safety

The proprietor of the IMM has to make sure andverify that the operator is aware of the safetyinstructions and potential hazards and followsthe operating manual at regular intervals.

Even if the IMM is only subject to slightmodifications in terms of position it should bedisconnected from any power supply.Reconnect all power supplies according to theoperating manual before restarting the machine.

When disposing of the IMM to a third party (orcompany), the Operating Manual must also behanded over. It is recommended to have awritten confirmation of this.

Installation

For installation, dismantling, modification,adaptation, and maintenance work parts,components or the entire IMM has to besecured and carefully attached to the lifting gearso as to prevent any dangers from arising. Onlyuse appropriate lifting gear in proper workingorder with sufficient carrying force. Personnel orother persons must by no means stand or workunder suspended loads.

Loads may only be fastened, secured andtransported by experienced, authorised andtrained personnel.

The IMM may only be lifted using the liftingpoints described in Chapter "Transport -Installation".

Before installation of the IMM the safetymeasures detailed in DIN EN 292-2, Para. 6.1.2are to be observed.

After electrical work or repair, the safety devicesmust be tested (e.g. earthing resistance).

Operation and maintenance

All work is principally to be carried out when theIMM is shutdown. The appropriate shut downprocedures are to be followed.

Before starting work on the IMM its drive andperiphery equipment must be secured againstaccidental reconnection, e.g. using a padlock onthe main switch.

Before reconnecting the IMM the safety devicesmust always be checked for their properfunction.

Before putting into operation after repair it mustbe verified that all the safety devices are inplace according to regulations.

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

If the ejector or core pullers are operated withthe safety gate open, it must be ensured thatthere are no pinching or crushing points on themould.

Safety


Chapter - 2Page - 3

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

The operator has a duty to ensure that electricalmotors and components do not come in contactwith any liquids.

Carefully clean the environment, especiallyconnections and fittings before servicing theplant.

Cleaning materials are hazardous to health andflammable. The manufacturer’s instructions areto be followed without fail. Do not useaggressive cleaning agents. Use non-fibrouscleaning cloths.

When using oils, greases or other chemicalsubstances, follow the safety regulationsapplicable to this product.

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

Always tighten screw connections which havebecome loose during operating andmaintenance work. Check pipework for leaks,loosened screw connections, chafe marks, anddamage. Remedy detected defects immediately.

Safety instructions with respect to personnel

All persons involved with the IMM on theoperator’s premises, whether for installation,dismantling, commissioning, operation,maintenance (inspection, service and repair)must first read and understand the appropriateOperating Manual, especially Chapter "Safety".The proprietor of the machine is advised to havethis confirmed in writing.

The IMM may only be operated, maintained andrepaired by authorised, trained personnel.Personnel must have undergone specialinstruction about possible hazards.

Personnel to be trained, instructed or who havenot yet finished the professional training mayonly work at the IMM if supervised byauthorised, trained and instructed staff.

The operators must wear their hair tied back,close-fitting clothes and must not wear anyjewellery including rings. There is a danger ofinjury, e.g. becoming trapped or caught.

Responsibilities for installation, dismantling,commissioning, operation, and maintenancemust be clearly defined and adhered to so thatno "grey areas" arise on the subject ofresponsibilities for safety.



Chapter -2Page - 4

Safety

For all work involving installation, dismantling,modification and maintenance, the IMM is to beswitched off at the main switch and securedagainst accidental reconnection (e.g. by using apadlock on the main switch).

When undertaking work involving installation,dismantling, modification, operation andmaintenance, no flammable liquids may beallowed to come into contact with componentswhose high temperatures could cause a fire orexplosion risk.

Before any work involving installation,dismantling, modification and maintenance, theheating elements and their guards, mouldtemperature control units and their flow andreturn lines and their fittings must have cooledto a safe temperature.

The operator must protect him / herself fromburning hazards from the heating elements,heating-cooling devices and their covers, flowand return lines and their fittings and thehousings of electrical motors by wearingappropriate PPE (see DIN EN 407).

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

No working method which compromises thesafety of the IMM should be employed.

The operator has a duty to ensure that nounauthorised person works on the IMM.

The operating and other staff must always standat the front of the IMM on the operator’s sidewhile it is in operation.

It is forbidden to stand on the IMM or to reachinto the injection unit during operation.

The shut down procedures given in theoperating manual are always to be followed forall work on the IMM.

The operator is obliged to report at once anyalteration in the IMM which affects safety. Ifnecessary the IMM should be switched off atonce by operating the emergency stop buttonand the main switch.

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

Cleanliness and tidiness of the IMM are to beensured by appropriate instruction andmonitoring on the part of the proprietors of themachine.

The operator is obliged to observe all safetyregulations and danger signs at the IMM. Thesesigns must be complete and fully legible.

If the material hopper, the material feeder or thestuffing device are located higher than theaverage body height, climbing aids and workingplatforms which meet the legal safetyrequirements must be used for installation,dismantling, modification, maintenance andfilling. Do not use the IMM components asclimbing aid. When working at greater heightsproper equipment for proctection against fallingdown must be worn.

The operator has a duty to ensure that noforeign bodies enter the material hopper orbarrel throat.

Safety


Chapter - 2Page - 5

It is essential that the operator ensures properfitting of the nozzle or there may be a risk of itsshooting out.

When using Mouldmaster nozzles (nozzles inthe mould) the operator must ensure that thereare no pinching or crushing points.

In any work involving installation, dismantling,modification and maintenance, the followingpotential pinching and crushing hazards mayarise:

• Between the safety gate and machineframe on closing the clamping unit’ssafety gate(s)

• Between the purge guard and the nozzleplaten on closing the purge guard

• With hydraulic shut-off nozzles from themovement of their closing mechanism

• Between the nozzle and the fixed platenwhen moving the injection unit forwardwith the purge guard open

• In the area of the screw shaft and thrustbearing (axial bearing) when couplingthe screw

• Around the material outlet whenswinging the hopper in and out or slidingit backward and forwards

There is a crushing and/or shearing and/orimpact hazard in the machine well (below themould space) from:

• Moving parts of the mould which can bereached through the machine well

• Falling injection moulded parts

Safety regulations Hydraulics / pneumatics

The IMM is designed and built to the currentlyapplicable safety requirements of EuropeanStandard EN 982:1996 and is safe in operation.Hazards can, however, arise from the hydraulicsystem of this IMM if it is improperly used byuntrained personnel or if it is used for purposesfor which it is not designed. Thus all workinvolving installation, dismantling, modificationand maintenance may only be carried out by aqualified hydraulic or pneumatic technician.

Hydraulic technicians are persons who due tospecialised training and experience havesufficient knowledge in the field of oil hydraulicsand who are familiar with the relevant safetyregulations, regulations for the prevention ofaccidents, directives and generally approvedrules in technology, e.g. DIN standards.

Before opening hydraulic or pneumaticcomponents and hoses, the hydraulic unit hasto be relieved from pressure as described in thisoperating manual.



Chapter -2Page - 6

Safety

Compressed air pipework for the pneumaticsystem and water pipework for the cooling ofthe hydraulic system have to be expertlyinstalled and laid. Fittings, length and crosssection have to meet the requirements.

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

All pipework, hoses and screw connectionsshould be checked for leaks and damage visiblefrom outside at regular intervals. Remedydamage immediately. Hydraulic oil escaping athigh pressure can cause severe injuries andfires.

Hydraulic hoses and hose assemblies have tobe replaced at the intervals given in the"Maintenance" chapter, even if there are nodefects to be detected which affect safety.

Hydraulic hoses and hose assemblies must beprotected from damaging external influences.

The safety regulations for hydraulic hoses andhose assemblies according to DIN 20066 Part 4and 5, ZH 1/74 and EN 201 are to beparticularly carefully observed.

For this reason, all work involving installation,dismantling, modifications and maintenancemay only be carried out by personnel trained inthis field.

Work (repair, connection of a pressure gauge)on an IMM with pressure vessels(accumulators) must not be carried out until thehydraulic pressure has been released; i.e. thepressure in the accumulator(s) must havecompletely decreased.. Neither welding normechanical processing may be undertaken.

The pressure vessels must be subject toacceptance tests at their place of use by thetechnical standards organisation responsible inthe proprietor’s region before being put intooperation.

Pressure vessels may only be filled withnitrogen "N2". The use of other gases causesexplosion hazards.

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

The proprietor is responsible for the propercondition, operation and monitoring of thepressure vessel (e.g. regular testing). Therelevant pressure vessel regualtions can befound from Carl Heymans Verlag KG,Gereonsstr.. 18-32, 50670 Cologne, under orderNo.: ZH 1/400.

The operator must keep appropriate absorbentmaterials for use in the event of hydraulic oilspillages.

When disposing of used oil and lubricants thelegal requirements and regulations must beadhered to. The proprietor is responsible forproper waste disposal.

Safety


Chapter - 2Page - 7

Safety instructions for materials

The IMM is intended exclusively for theprocessing of polymeric materials as stated inthe "General information" chapter. Any other useis considered improper and any loss damage orinjury arising is the responsibility of thecompany. The manufacturer can accept noliability.

The operator is responsible for ensuring that noeasily drawn in material or explosive airmixtures may be near the inlet area of the screwbarrel heating or barrel temperature control(radial ventilators).

The operator has a duty to ensure that thecooling fans are in good technical condition withundamaged electrics.

When processing plastics which give rise toharmful gases, dusts or vapours, the proprietorof the machine has a duty to provide suitableextraction for the protection of operatingpersonnel.

Some plastics, if they are not properly dried,may spit material from the nozzle. Follow theplastic manufacturers’ instructions.

There is a burning hazard at operatingtemperature from:

• The nozzle

• Plasticised melt emerging from thenozzle

Provide appropriate protective clothing (DIN EN407).

Safety instructions for electrics

The electrical equipment on the IMM isdesigned and built to the currently validstandards EN 60204-1 and IEC 801-2 and issafe to operate. Hazards can, however, arisefrom the electrical system of this IMM if it isimproperly used by untrained personnel or isused for purposes for which it is not designed.Thus all work involving installation, dismantling,modification and maintenance may only becarried out by a qualified electrician (as definedin DIN VDE 0105 or DIN EN 60204-1).

The electrical equipment may only beconnected to a mains supply which correspondsin terms of current type, voltage and frequencyto the specifications on the IMM specificationplate. The electrical supply lines must meet therequirements.

The IMM must be switched off at the mainswitch before all work involving installation,dismantling, modification and maintenance.Check the electrical equipment for lack ofvoltage, then earth it and and short it out.

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

The electrical equipment is to be checked atregular intervals. Defects such as looseconnections or scorched cables must beimmediately remedied.



Chapter -2Page - 8

Safety

For reasons of safety, the operator must log offfrom the control unit after finishing the settingmode in order to prevent unauthorised personsfrom data entry.

For all work involving installation, dismantling,modifications and maintenance, the legalrequirements and regulations must be observed.

Safety instructions for changing nozzle,screw and barrel

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

When fitting or removing the nozzle, screw orbarrel it is essential to activate and use the IMMwithout the guarding on the injection unit.

The proprietor therefore has a duty to ensurethat the danger zone is adequately protectedand that no unauthorised persons enter thiszone.

Before moving the injection or nozzle contactcylinders with their guarding removed it must beensured that no tools or other materials are lefton the IMM.

Whilst moving the injection piston or nozzlecontact cylinder with the injection unit guardingremoved, the operator must maintain a safedistance.

Immediately after moving the injection or nozzlecontact cylinders with their guarding removed,the IMM must be switched off again andsecured against accidental reconnection.

If proper procedures are not followed in thefitting or removal or in handling the nozzle,screw, barrel or the respective heating elementsthere is a risk of injury or burning. Wearappropriate protective clothing (see DIN EN407).

When fitting or removing the nozzle, screw andbarrel, no tools may be used which could causedamage to these components.

Safety


Chapter - 2Page - 9

2.2 Safety grid monitoring

This monitoring controls the appropiate taskaccording to the following components:

• The alternating position of the positionswitch (230S3, 230S4)

• The limit switch of the hydraulic interlock(position monitoring valves 240Y1, S240which are operated directly by theposition switch 240S1)

• The restricted guidance contactor relay(230K1, 230K2) in the valve circuit of theclamping unit

If a defect is detected in the above componentsit will be displayed on the error message "Safetygrid".

2.3 Pneumatic Safety Hood andSafety Bar (PLUS-V)

The clamping unit is completely covered toprevent accidents.

The working area between nozzles and mould-mounting-plates is secured by a plexiglasssafety hood with a safety bar, which ensures agood view of the working area.

To avoid risk of injury when the safety hood isclosed, an electric monitored safety bar can befound on its underside. In the event of anobstruction a counter movement willautomatically be triggered and the safety hoodopened.

To prevent accidents, the opening and closingmovements of the opened safety hood are bothelectronically and hydraulically disabled. Inaddition the closing movements are preventedby a mechanical closing interlock.

Monitoring unit safety bar

1. Function

The electronics of the switching equipmentmonitor the electrical resistance of a connectedcontact element with a defined static current. Ifthe required static current flows, both outputrelays are triggered (ON) and the yellow lightdiodes "Relays ON" are illuminated. If thecontact element is activated, the output relaysare no longer triggered (OUT) and the yellowlight diodes go out.



Chapter -2Page - 10

Safety

2. CharacteristicsContact element - inputR = 1200 WStatic current contact elementI < 5mAshift point when pressed500 W < R < 700 Wshift point on disconnection1,9 kW < R < 2,5 kW

3. Test:

• Both output relays must be activatedwhen contact elements are ready foropeation.and illuminate the yellow LEDs"Relays ON"

• Touch contact element Both outputrelays must be released, both yellowLEDs "relays ON" must go out

4. Trouble shooting and Measures

• Relay does not switch on

• LED does not light up

Check whether the supply voltage to terminals11, 12 is connected correctly and that itcorresponds to the device voltage of the side-name-plate.

Check whether the contact element isconnected correctly to terminals 8, 9 and thatthe terminal voltage amounts to approximately4 V DC. If a higher voltage is supplied, theterminating resistor of the contact element mustbe checked. The device only operates with aterminating resistor of 1,2 KW.Nevertheless if the device does not switch on,the switching equipment is faulty and must bereplaced.

• If the LED remains constantlyilluminated, it indicates an error

The switching equipment is faulty and must bereplaced.

2.4 Safety hood and guard

The clamping unit is completely covered toprevent accidents. The frontside part of thecover is formed as a single-piece coveringhood. By loosening 4 screws this can beremoved to be adjusted.

The working area between nozzles and mould-mounting-plates is secured by two sliding safetyhoods which allow a good view of the workingarea.

The front side of the saftey hood is kept closedby a magnet. The locking force is reduced afterapproximately 0,5 sec to allow a slight openingin the safetyhood.

In automatic mode (exception: in the machinesstarting position) or during a machinemovement, the safety gate cannot be opened.

To prevent accidents, all movements , electricas well as hydraulic, are disabled when thesafety hood is open (closing, opening, ejecting,nozzle, metering, decompression and injectionmovements).

Safety


Chapter - 2Page - 11

2.5 Robot protective equipment(option)

According to safety regulations, for theprotection of the operator, the robot must befused with appropiate safety devices tp preventcontact with the system.

Caution"We refuse to assume any responsibility incase of a failure to observe this safetydevice!"

Appropiate protective equipment has thereforebeen designed, in case required, which isinstalled in your Robot. If the customer wishesthe robot to be delivered without the safetydevice, the customer, as well as the user, mustalways take the necessary safety measureshimself.


The safety devices of the machine can onlyfulfill their purpose if their faultless operation canbe guaranteed. It is therefore necessary tocheck their effective function at all times.

1. Checking electrical closing interlock

• Limit switches securely fixed

2. Checking hydraulic interlock

• Directional valve securely fixed

• Electrical limit switches securely fixed(only with PLUS-V)

3. Checking mechanical scotch

• Smooth operation of the stop on thenozzle platen

• Switching distance of the activatedinitator 2 mm (only with PLUS-V)

CautionIf a fault appears on the machine whichcauses the mechanical scotch to come intooperation, Battenfeld Customer Service orthe responsible agent must be contacted!

4. Checking safety hood

• Limit switches securely fixed

• Smooth operation of the closingmovement (only with PLUS-V)

5. Checking safety hood and guard

• Security of all fixing bolts andundamaged condition

6. Checking robot protective equipment(option)

• Security of all fixing bolts andundamaged conditiosonably foreseeableunfavourable installation / use



Chapter -2Page - 12

Safety

2.7 Table for risk assessment

Reasonably foreseeable unfavourable inst

Reasonably foreseeable faults in installation and electrical connection

Use of unsuitablematerials

Use of unsuitablemoulds;Mould not installed

Missing covers andlimit switches notworking

Operating error

Case

1

2

3

4

Measures

Warnings andallowed materialrange in theOperating Manual

Instructions in theOperating Manual

Warnings, labels,instructions in theOperating Manual


Consequence / otherhazards

Only if the warnings inthe Operating Manualare ignored

Damage to machinecomponents,

Burning hazard ifaccidentally touched orduring maintenancework, crushing hazardfrom closing movement

Loss of machine function

Hazard

IMM overload;possible fire orexplosion, emissionof health hazardousproducts

IMM overload,uncertain operatingconditions, escape ofhot material

High surfacetemperatures,moving parts duringclosing movement

- - -

Case

1

2

Measures



Consequence /other hazards

Permanent machinedamage

Permanent machinedamage

Hazard

no properfunctioning

Blockage,overheating

Electrical supply(voltage, frequency,cable size)

Unsuitable coolant(Water flow rate,pressure)

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

Technical Data

A: PB2GB0CA.P65B: PB2DE0CA.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter -3Page - 1

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


Machine type / control see cover sheetMachine No. / year of construction see cover sheetMachine weight gross/nett see foundation and installation planMain dimensions of the IMM see foundation and installation planNoise level (DIN EN ISO 3744 46) 72 dB(A)

3.2 Hydraulic equipment

Hydraulic oil, tank volume HPL 46, 125 l (33 gal)Oil temperature min / max min 35 °C (95 °C); max. 65 °C (149 °C)Oil cooling trigger temperature 45 °C (104 °F)


Power, hydraulic pump 7,5 kW, 40 l/min (10,6 gal/min)Motor voltage see electrical spec. plateFrequency: see electrical spec. plateScrew barrel temperature max. 350 °C ( 662 °F) (option 450 °C, 842 °F)

3.4 Water system

Oil cooler: Cooling water consumption max. 80 l/h (21 gal/h)Cooling water supply max. 30 °C ( 86 °F)

Cooling water distrib.: Cooling water supply Ø 1/2“, Ø 13 mm, max.10 bar (145 psi)Cooling water return Ø 1/2“, Ø 13 mm

A: PB2GB0CA.P65B: PB2DE0CA.P65E: 180202 / Ruder


Chapter -3Page - 2

Technical Data

3.5 UNIFEED material feeder(option)

Throughput

At 6 bar (87 psi) pneumatic pressure, 100 %demand and a nominal 19,05 mm (0.75 inch)hose of which 4 m (13 ft) are vertical.

Air consumption

1 - V at 100 % demand2 - V at 50 kg (52,16 kg) material / h3 - V at 35 kg (80 lb) material / h

Noise level

250

200

150

100

50

0

Air consumed Qn / min

Figure: PL-0035.WMF

5(72)

4(58)

3(44)

7(101)

6(87)

1

2

3

Pneumatic pressure (abs.)bar (psi)

10(33)

20(65)

0

Figure: PL-0033.WMF

kg / h

250

200

150

100

50

Hose length m (ft)

Throughput PA

30(98)

40(130)

50(163)

60(195)

lb / h

562

450

338

225

112

Figure: PL-0034.WMF71

70,5

70

69,5

69

68,5

68

Noise leveldB / A

5(72)

4(58)

3(44)

Pneumatic pressure (abs.)bar (psi)

7(101)

6(87)

Technical Data


Chapter -3Page - 3

3.6 Injection unit

m m inch 18 0,71 2 2 0,87 2 5 0,98

bar ps i 2431 35258 1627 23597 1260 18274

ccm cu in 25,4 1,55 38 2,32 49 2,99

g o z 23,1 0,81 34,5 1,22 44,6 1,57

g o z 18 0,63 27 0,95 34,5 1,22

-

m m inch 150 5,91 150 5,91 150 5,91

kN sh tn 22 2,42 22 2,42 22 2,42

m m inch 100 3,94 100 3,94 100 3,94

kW

-

M ax. screw speed m in-1

Screw to rque Nm lbf ft 160 118,01 160 118,01 160 118,01

P last icising rate (P S) g/s lb/h 6,5 51,59 9,5 75,40 12 95,24

M ax. screw speed m in-1

Srew to rque Nm lbf ft 210 154,89 210 154,89 210 154,89

P last icising rate (P S) g/s lb/h 5,2 41,27 7,6 60,32 9,6 76,19

ccm/s cu in/s 38,4 2,34 57,3 3,50 74 4,52

B a rre l he a t ing po we r

S c re w dia m e t e r

S pe c if ic inje c t io n pre s s ure

20

2,76

16 14

Injection unit 50

420

N o zzle pa t hN o zzle c o nt a c t f o rc e

T he o re t ic a l s t ro k e v o lum e

M a x. in je c t io n we ight ( po lys t yre n

M a x. in je c t io n we ight ( po lye t hyle

L/ d ra t io no f s c re w

S c re w s t ro k e

In je c t io n ra t e int o a ir

1 + 2

336

P B _GB 01.XLS

N um be r o f c o nt ro lle d s ys t e m s

S c re w driv e ( s t a nd.)

S re w driv e ( h igh t o rque )

mm inch 18 0,71 2 2 0,87 2 5 0,98 3 0 1,18

bar psi 3038 44062 2034 29500 1575 22843 1094 15867

ccm cu in 25,4 1,55 38 2,32 49 2,99 70,6 4,31

g oz 23,1 0,81 34,5 1,22 44,6 1,57 64,2 2,26

g oz 18 0,63 27 0,95 34,8 1,23 50,1 1,77

-

mm inch 150 5,91 150 5,91 150 5,91 150 5,91

kN sh tn 27,5 3,03 27,5 3,03 27,5 3,03 27,5 3,03

mm inch 100 3,94 100 3,94 100 3,94 100 3,94

kW

- 1 + 2

M ax. screw speed min-1

Screw to rque Nm lbf ft 200 147,51 200 147,51 200 147,51 240 177,01

P lasticising rate (P S) g/s lb/h 6,5 51,59 9,5 75,40 12 95,24 13 103,17

M ax. screw speed min-1

Srew to rque Nm lbf ft 273 201,35 273 201,35 273 201,35 326 240,45

P lasticising rate (P S) g/s lb/h 5,2 41,27 7,6 60,32 9,6 76,19 10,4 82,54

ccm/s cu in/s 38,4 2,34 57,3 3,50 74 4,52 106,6 6,50

P B _GB 01.XLS

336

Injection unit 75

420

N o zzle pa thN o zzle co nt ac t fo rc e

S c re w s t ro k e

S c re w diam e t e r

S pec if ic inje c t io n pre ssure

B a rre l he a t ing po we r

N um be r o f c o nt ro lle d sys te m s

S crew drive (s tand.)

Inje c t io n ra te into a ir

S rew driv e (high t o rque )

T heo re t ic a l s t ro ke vo lum e

M ax. injec t io n we ight (po lys tyren

M ax. injec t io n we ight (po lye thyle

L/ d ra t io no f s c rew 20

2,76

16 14 13,5



Chapter -3Page - 4

Technical Data

3.7 Clamping unit

C la m ping fo rc e kN sh tn 2 5 0 27,55 3 5 0 38,57

O pe ning fo rc e kN sh tn 29,5 3,25 29,5 3,25

M o unt ing pla t e n s ize mm inch 470 x 280 18,50 x 11,02 470 x 280 18,50 x 11,02

T ie ba r dia m e te r mm inch 60 2,36 60 2,36

D is ta nc e be twe e n t ie rba rs mm inch 270 10,63 270 10,63

M o uld he ight a djus ta ble f ro m ... to mm inch 150 .. 250 5,9 .. 9,8 150 .. 250 5,9 .. 9,8

O pe ning s t ro k e a t m a x. m o uld he ight mm inch 200 7,87 200 7,87

M a x da ylight mm inch 450 17,72 450 17,72

M a x. e je c to r f o rc e kN sh tn 26 2,87 26 2,87

Eje c to r s t ro k e mm inch 100 3,94 100 3,94

Clamping unit PLUS 250 - PLUS 350

P B _GB 02.XLS

C la m ping fo rc e kN sh tn 2 5 0 27,55 3 5 0 38,57

O pe ning fo rc e kN sh tn 29,5 3,25 29,5 3,25

M o unt ing pla t e n s ize mm inch 470 x 280 18,50 x 11,02 470 x 280 18,50 x 11,02

T ie ba r dia m e te r mm inch 60 2,36 60 2,36

D is ta nc e be twe e n t ie rba rs mm inch 270 10,63 270 10,63

M o uld he ight a djus ta ble f ro m ... to mm inch 200 .. 250 7,9 .. 9,8 200 .. 250 7,9 .. 9,8

O pe ning s t ro k e a t m a x. m o uld he ight mm inch 200 7,87 200 7,87

M a x da ylight mm inch 450 17,72 450 17,72

M a x. e je c to r f o rc e kN sh tn 26 2,87 26 2,87

Eje c to r s t ro k e mm inch 100 3,94 100 3,94

P B _GB 02.XLS

Clamping unit PLUS 250 V - PLUS 350 V

Technical Data


Chapter -3Page - 5

3.8 Injection pressure charts

Injection assembly 50

Screw D = 18 mm (0.709 inch)2431 bar (35250 psi)



1

2

3

3 2 1

140

126

112

98

84

70

56

42

28

14

400200 1200 1400 200018001600 2200 24001000800600

2900 5800 8700 11600 14500 17400 2320020300 26100 29000 31900 34800

barpsi

Figure: PL-0015.WMF

barpsi

2030

1827

1624

1421

1218

1015

812

609

406

203



Chapter -3Page - 6

Technical Data

Injection assembly 75





1

2

4

3

400200 1200 1400 200018001600 2200 2400 3000280026001000800600 bar2900 5800 8700 11600 14500 17400 2320020300 26100 29000 31900 34800 37700 4350040600 psi

4 3 2 1Figure: PL-0016.WMF

175

158

140

123

105

88

70

53

35

18

barpsi

2538

2284

2030

1776

1523

1269

1015

761

508

254

Technical Data


Chapter -3Page - 7

3.9 Injection speed chart

These technical data refer to the injection flow in the open.

100

90

80

70

60

50

40

30

20

10

100908070605040302010

Screw D = 30Figure: PL-0017.WMF

cm3 / sec(inch3 / sec)

v

(6,10)

(5,49)

(4,88)

(4,27)

(3,66)

(3,05)

(2,44)

(1,83)

(1,22)

(0,61)

mminch9,18,27,36,45,44,53,62,71,80,9

55

49,5

44

38,5

33

27,5

22

16,5

11

5,5



v [%]

(3,36)

(3,02)

(2,68)

(2,35)

(2,01)

(1,68)

(1,34)

(1,01)

(0,67)

(0,34)

100908070605040302010 mminch9,18,27,36,45,44,53,62,71,80,9

35

31,5

28

24,5

21

17,5

14

10,5

7

3,5



v [%]

(2,14)

(1,92)

(1,71)

(1,49)

(1,28)

(1,07)

(0,85)

(0,64)

(0,43)

(0,21)

100908070605040302010 mminch9,18,27,36,45,44,53,62,71,80,9

70

63

56

49

42

35

28

21

14

7



(4,27)

(3,84)

(3,42)

(2,99)

(2,56)

(2,14)

(1,71)

(1,28)

(0,85)

(0,43) v [%]

100908070605040302010 mminch9,18,27,36,45,44,53,62,71,80,9



Chapter -3Page - 8

Technical Data

3.10 Injection volume chart

70

63

56

49

42

35

28

21

14

7


(4,27)

(3,84)

(3,42)

(2,99)

(2,56)

(2,14)

(1,71)

(1,28)

(0,85)

(0,43)

cm3

(inch3)

s

100908070605040302010 mminch9,18,27,36,45,44,53,62,71,80,9

40

36

32

28

24

20

16

12

8

4


cm3

(inch3)

(2,44)

(2,20)

(1,95)

(1,71)

(1,46)

(1,22)

(0,98)

(0,73)

(0,49)

(0,24) s [%]

100908070605040302010 mminch9,18,27,36,45,44,53,62,71,80,9


cm3

(inch3)

25

22,5

20

17,5

15

12,5

10

7,5

5

2,5

(1,53)

(1,37)

(1,22)

(1,07)

(0,92)

(0,76)

(0,61)

(0,46)

(0,31)

(0,15) s [%]

100908070605040302010 mminch9,18,27,36,45,44,53,62,71,80,9


cm3

(inch3)

s

1009080706050403020 mminch9,18,27,36,45,44,53,62,71,8

50

45

40

35

30

25

20

15

10

5

(3,05)

(2,75)

(2,44)

(2,14)

(1,83)

(1,53)

(1,22)

(0,92)

(0,61)

(0,31)

Technical Data


Chapter -3Page - 9

kN

250

225

200

175

150

125

100

75

50

25

27,5

24,8

22,2

19,3

16,5

13,8

11,0

8,2

5,5

2,8

shtn

21

305

barpsi

Figure: PL-0018.WMF

p

42

609

63

914

84

1218

105

1523

126

1827

147

2132

168

2426

189

2741

210

3045

3.11 Screw speed chart

3.12 Clamping force charts PLUS 250 / PLUS 250 V

Figure: PL-0018.WMF

10 20 30 40 50 60 70 80 10090

1

2

420

378

336

294

252

210

168

126

84

42

v [%]

min-1

Screw speed 420min-1 (standard torque)

Screw speed 336min-1 (stronger torque)



Chapter -3Page - 10

Technical Data

kN

350

315

280

245

210

175

140

105

730

35

38,5

34,7

30,9

27,0

23,2

19,3

15,4

11,6

7,7

3,9

shtn

21

305

barpsi

Figure: PL-0018.WMF

p

42

609

63

914

84

1218

105

1523

126

1827

147

2132

168

2426

189

2741

210

3045

3.14 Clamping speed charts

3.13 Clamping force charts Plus 350 / Plus 350 V

Figure: PL-0018.WMF470

423

376

329

282

235

188

141

94

47

10 20 30 40 50 60 70 80 10090

Plus 250Plus 350

Plus 250 VPlus 350 V

(18,50)

(16,65)

(14,80)

(12,95)

(11,10)

(9,25)

(7,40)

(5,55)

(3,70)

(1,85)

mm / secinch / sec

v [%]

Technical Data


Chapter -3Page - 11

3.15 Mould dimensions

Minimum effective mould diameter

With the 2 clamping cylinders the clampingsystem ensures a gentle application and evendistribution of the clamping force.

These functions can only be fulfilled if theeffective diameter of the mould does not fallbelow a certain minimum, so that "wrap-round“of the mould mounting platens is kept withinacceptable limits.

Since the dimensional accuracy of the injectionmoulded parts, the loading on the mould and themould’s function especially with complex tooling(multi-plate tools, side actions) are affected bythe wrap-round of the mould mounting platens,keeping to these guidelines will ensure thatunacceptable overloading of the clamping unitand the mould are avoided.

Thus the following minimum mould dimensionsshould be observed, bearing in mind therequired clamping force in respect of mouldloading and energy consumption.

PLUS 250 - PLUS 250 Vmin. mould diameter 160 mm (6.3 inch)

PLUS 350 - PLUS 350 Vmin. mould diameter 160 mm (6.3 inch)

Special attention must be paid to off-centremoulds and to parallelism of the mould andmould parting surfaces. Any deficiency here cancause deformation of both the mould and theclamping unit, with a very detrimental effect onthe service life of sealing and guidingcomponents.

Maximum mould weights

The required dimensional accuracy of theinjection moulded part, the loading and themould’s function especially with complex tooling(multi-plate tools, side actions) are heavilydependent upon the parallelism of the mouldmounting platens.

The degree of parallelism required byEUROMAP 9 will be achieved if the followingmould weights are not exceeded:

PLUS 250 - PLUS 250 Vmin. mould weight 140 kg (315 lb)

PLUS 350 - PLUS 350 Vmin. mould weight 140 kg (315 lb)

The total weight of the mould half on the movingplaten must not be more than 2/3 of the totalmould weight given in the table.



Chapter -3Page - 12

Technical Data

Material Factor Material FactorABS 0.88 PP + 40% Talcum 0.98CA 1.02 PP + 20% GF 0.85

CAB 0.97 PS 0.91PA 0.91 PVC-rigid 1.12PC 0.97 PVC-plasticised 1.02PE 0.71 SAN 0.88

PMMA 0.94 SB 0.88POM 1.15PP 0.73 PF 1.3

PP + 20% Talcum 0.85 UP 1.6AHGB031

3.18 Torque settings for bolts

The torques are based on a frictional factor of0.10 (µm total) for untreated, Molykotelubricated and cadmium electroplated surfaces,but not for slightly oiled ones.

3.19 Mould mounting dimensions

Please refer to the appendix of chapter.

3.20 Foundation and installationplan

Please refer to the appendix of this chapter.

3.16 Conversion table for shotweights

The maximum shot weights (g/oz) arecalculated by multiplying the theoretical shotvolume (cm3/cu inch) by the factors givenabove. The grey fields contain the factors forthermoset plastics.

3.17 Weights of screws and barrels

Load requirements for lifting gear for barrelsincluding screws when changing screws andbarrels.

[mm] [inch] [kg] [lb]

18 0,71 20 45

22 0,87 20 45

25 0,98 20 45

30 1,18 20 45PB_GB3.XLS

S c re w dia m e te r We ight

[Nm] [lbf ft]

M 10 42 31

M 12 72 53

M 14 114 84

M 16 174 128

M 20 340 251

M 24 580 428

M 27 855 631

M 27 x 2 900 664

M 30 1160 856

M 33 x 2 1680 1239

M 36 2030 1497

M 36 x 2 2200 1623

M 39 2620 1932

M 42 3240 2390

M 48 4890 3607

TM _GB05.XLS

N o m ina l t hre a d s izeT o rque s e t t ing fo r f it t ing te ns ile

s t re ngt h c la s s 8 .8

Transport - Installation

A: PB2GB0DA.P65B: PB2DE0DA.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter - 4Page - 1

4.0 Transport - Installation


After delivery of the injection moulding machine(hereinafter called IMM) it should be checkedimmediately for any damage and forcompleteness.

The IMM delivery kit includes:

• Operating manual

• Levelling mounts (option)

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

We would recommend to have the installation ofthe IMM carried out by Battenfeld personnel. Wecan accept no responsibility for loss, damage orinjury resulting from improper installation.

The foundation plan and installation plan can befound in the chapter "Technical Data". Thischapter includes, amongst other information, theweights and dimensions which should be takeninto account when installing the IMM. T4

he installation drawings have been simplified.

4.2 Storage

The IMM is packed as standard to withstandtransportation without damage. However itshould be commissioned immediately afterhandover from the transport company.

If it is to be stored for a longer period, ourcustomer service department has to becontacted.

4.3 Unloading

Trouble free operation and some clauses ofthe guarantee are conditional upon properunloading of the IMM!

The IMM may only be lifted and movedhorizontally and using the provided liftingand transport elements. It is essential thatthe slings are prevented from slipping!

The safe working load of the crane and theslings must equal or exceed the weight ofthe IMM. See "Technical Data" chapter,Foundation and installation plan for details!

Follow without fail the transport plan fixed tothe IMM!

No persons may stand or linger under thesuspended load!

The complete IMM may only be placed on alevel surface capable of supporting theappropriate load!

A: PB2GB0DA.P65B: PB2DE0DA.P65E: 180202 / Ruder


Chapter - 4Page - 2


4.5 Transporting the IMM

If the transport plans do not agree with thefollowing descriptions and diagrams, thetransport plans in the "Technical Data"chapter are to be taken as definitive!

Forklifts / Crane transport

When using fork lifts, the prescribed lifting pointsgiven in the "Foundation and Installation Plan"in Section "Technical Data" must be used.

PLUS H

PLUS V

The complete IMM may only be placed on alevel surface capable of supporting theappropriate load.

Trouble free operation can not be guaranteed ifthe IMM is placed on an uneven floor.

If there is no level surface, a foundation must bebuilt according to the "Foundation andInstallation Plan", see "Technical Data" Section,to provide a level base.

If transport to the final location is impossiblewith cranes, the IMM must be supported underits entire base for moving across the floor.

4.4 Space requirement plan

The exact space requirement can be taken fromthe "Foundation and Installation Plan" in the"Technical Data" chapter.

For maintenance work 0,6 m (25 inch), 1,3 m(56 2inch), must be allowed.


A: PB2GB0DA.P65B: PB2DE0DA.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter - 4Page - 3

4.6 Installing the IMM

The IMM may only be installed in a dry, dust-free environment above freezing point.

A special foundation is not required. However, itmust have a level surface and support shocks,as well as the weight of the machine.

Levelling mounts

The levelling mounts (option) allow installationof the IMM without fixing it to the floor. Theyenable the IMM to be levelled, act as shockabsorbers and protect the environment byreducing the noise level. The mounts facilitateinstallation and removal of the IMM since theyare not fixed to the floor and are adjustable forheight.

4.7 Removing preservativeagents

General information

All unplated moving parts and guides (tie-bars,piston rods, etc.), must have the rust protectionremoved, using cloths soaked in white spirit,paraffin (kerosene) or similar solvents.

Small components delivered with the IMM suchas screw tips and check rings are protected bywax dipping. The wax coating should beremoved before use.

CautionEven a single stroke without removing thecorrosion protection can drive it into theguides and lead to wear!

If not expertly preserved warranty isinvalidated.

These cleaning fluids are consideredhazardous to health and are flammable.Follow the manufacturers’ instructions!

The local regulations must be observedwhen disposing of these liquids and clothssoaked in them!

A: PB2GB0DA.P65B: PB2DE0DA.P65E: 180202 / Ruder


Chapter - 4Page - 4


Clamping unit

1 Mould mounting surfaces

2 Ejector coupling and guides

3 Tiebars

4 Clamping platen slideways

5 Stroke transducer rod

6 Rack of the mechanical scotch bar(option)

Injection side

1 Nozzle movement cylinder piston rods

2 Carriage slideways injection unit

3 Barrel, screw shaft and coupling

4 Piston rods Injection cylinder

5 Material hopper (inside)

4.8 Levelling the IMM

General information

A machine spirit level with an accuracy of0.1 mm/m (0.004 in/3.281ft) and a true straight-edge are essential for levelling the IMM. Inaddition the machine must be equipped withlevelling mounts (option).

Injection unit

The centricity of the nozzle has been set in thefactory, but must still be checked after movingthe IMM, and readjusted if necessary ( seestructure and function chapter).

• Fill with hydraulic oil; see "Hydraulicunit"

• Connect power; see "Electricalequipment" paragraph

• Select "Setting" mode

• Move the injection unit back until thenozzle is flush with the nozzle sidemould mounting surface

• Switch off at the main switch and secureagainst accidental reconnection


A: PB2GB0EA.P65B: PB2DE0EA.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter -4Page - 5

CautionThe IMM’s hydraulic unit requires oil of thecleanliness class 15/12 to ISO 4406.Contamination above this cleanliness classby improper filling or use of unsuitablehydraulic oil will invalidate the guarantee!

If hydraulic oil becomes contaminated withwater it will be of inferior quality and mustnot be used any further!

The hydraulic tank may only be filled withhydraulic oil as detailed in the "Maintenance"chapter. The required oil volume is 125 l or33 gal.

CautionTest the hydraulic oil for the possibleingress of water!

Never switch the IMM on without hydraulicoil. Even the shortest period of running willdamage hydraulic equipment!

Before switching on for the first time thehydraulic pump housing(s) must be primedwith hydraulic oil via the leakage line!

4.9 Hydraulic unit

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

If the hydraulic system is not relieved ofpressure before work is started it may emptyexplosively with the risk of damage andinjury!

If the clamping platen, nozzle and screw are notin one of their limit positions then the hydraulicsystem is relieved from pressure. Any residualpressure can be released by carefully loosening(but not completely undoing) a hydraulic fitting.

Secure the main switch in the OFF position sothat it cannot be accidentally reconnected bypressing the red locking bar.

Oil filling

Unscrewing the coverplate on the underside ofthe maschine allows access to the filling-ventingfilter. 125 l (33 gal) of hydraulic oil is used forthe first filling of the integrated oil-tank.

A: PB2GB0EA.P65B: PB2DE0EA.P65E: 180202 / Ruder


Chapter -4Page - 6


CautionBefore switching on the hydraulic pump thehydraulic motor’s direction of rotationshould be checked!

CautionBefore switching on the IMM the hydraulicoil should be allowed to "stand" for approx.1 hour to let the air trapped during fillingescape!

Air bleeding

After filling the oil tank air must be bled from thehydraulic system.

• Connect power; see "Electricalequipment" paragraph

• Connect cooling water; see "Watersystem" paragraph

• Press the "Hydraulic start" key to switchon the hydraulics

• Press the "Setting" key

• Open and close all safety gates

• Drive the clamping platen, nozzle andinjection piston to and fro over theirwhole stroke several times

The IMM is effectively bled when no oil foamappears in the hydraulic tank, movements aresmooth and there are no strange noises.

The oil level should be checked after bleedingand topped up if necessary. Care must be takento use the same oil type.

Any oil leaks arising after a few hours’ runningare usually cured simply by tightening thefittings.

Core-puller (option) - see chapters "Structureand function" / "Hydraulic unit"

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



Chapter -4Page - 7

4.10 Water system

CautionWhen installing water pipework note thecorrosion stability of metallic materialsagainst water in accordance with DIN 50930!

Water quality

If there are deviations from the followingguidelines please contact our technicalcustomer service or one of our subsidiaries. Theaddresses can be found in the "Customerservice" chapter.

pH value: 6,5 - 9

Water hardness: < 1,8 mmol / l (681 ppm / gal)

Solids: < 0,03 ‰ (30 ppm)

Filter mesh: < 100 µm (0.004 inch)

In the relation of solids content to waterhardness it should be noted that the harder thecooling water is, the lower the solids contenthas to be. If the solids content is above 0.003 %(30 ppm), a water filter with a mesh size of< 100 µm (0.004 inch) must be installed in thesupply line.

It is also recommended to add a corrosioninhibitor to the cooling water (e.g. Ferrophos8579 from Henkel).

We recommend ethylene glycol type 420 as anantifreeze (60 % water and 40 % ethyleneglycol). This is suitable for a temperature rangedown to -30 °C (-22 °F) and is also a corrosioninhibitor.

Cooling water connection

If the pressure in the cooling water system isnot released before starting work, this maycause an explosive pressurisation with therisk of damage and injury!

The cooling system for the IMM can also be runas a closed cooling system. The purest, mostchalk-free water should be used. The requirednominal diameters of the hoses are quoted inthe "Technical Data" chapter. The bore of theflow and return lines must not be smaller thanthose of the connections on the IMM.

Cooling water flow controls

The cooling water flow controls provide coolingwater for various users, such as mould, screwbarrel, etc., from a common water supply. Thecooling water flow rate and thus the differenttemperatures of the various consumers arecontrolled by the appropriate hand-wheels.

Burning hazard if touched! Wear suitablepretective clothing with water temperaturesabove 50 °C (122 °F)!



Chapter -4Page - 8


Injury hazard to operating and otherpersonnel and possible damage to coolingwater flow control if used at impropertemperatures and pressures!

The cooling water pressure must be set fordifferent temperatures according to the followingtable:

Temperature max. pressure

40 °C (104 °F) 10 bar 145 psi

60 °C (140 °F) 8 bar 116 psi

80 °C (176 °F) 6 bar 87 psi

100 °C (212 °F) 4 bar 58 psi

• The cooling water hoses must be routedso that unhindered water supply andreturn are ensured. Kinks and squeezingwill prevent the optimised flow of thecooling water

Water assemblies have to be expertlyinstalled and laid. Fittings, length and crosschapter have to meet the requirements!

• Make sure the hoses are long enough toallow for movement of the various units

• The hoses must be suitable for thesystem pressure (max. 10 bar - 145 psi)and the temperatures used (max. 100 °C- 212 °F)

Before the cooling water flow control isconnected it must be ensured that the hand-wheels are closed clockwise.

Next, the various users are connected to thecooling water flow controls.

Now the cooling water flow control is connectedto the cooling water system. By turning the twohand-wheels counterclockwise, the coolingwater flow is opened and the required flow ratecan be set.

Using a marker ring, the required flow rate canbe marked so that the desired flow rate can beset again easily after a user has been turned off.



Chapter -4Page - 9

The flow rate set can be calculated from thebobbin’s position in the water stream and thescale using the following chart.

Flow range of each circuit (default setting4 /min, 0,88 imp.gal/min):

Brass bobbin 0,5 - 8 l/min(0,11 - 1,76 imp.gal/min)

Temperature max. 80 °C (176 °F)

Pressure: max. 10 bar (145 psi)

Oil cooling

The hydraulic oil is cooled in a heat exchanger.In the oil cooler cooling water is passed throughcooling coils immersed in the hydraulic oil.

A pilot solenoid valve regulates the water flow. Itstarts and stops the cooling water flow asnecessary to ensure constant oil temperature.

A temperature sensor in the hydraulic tankmeasures and monitors the oil temperature andsends the actual value to the IMM’s control unit.This in turn orders the solenoid valve to beopened or closed.

Water assemblies for cooling the hydraulicsystem have to be expertly laid andinstalled. Fittings, length and cross chapterhave to meet the requirements!

• The cooling water hoses must be routedso that unhindered water supply andreturn are ensured. Kinks and squeezingwill prevent the optimised flow of thecooling water

0 1 2 3 4 5 6 7 8 l/min

8

7

6

5

4

3

2

1



Chapter -4Page - 10


• The hoses must be suitable for thesystem pressure and the temperaturesreached in use

The IMM is most efficient at an oil temperaturebetween 45 °C and 50 °C (113 °F and 112 °F).The maximum water supply temperature mustnot exceed 30 °C (86 °F).

Cooling water consumption conditions:

Oil side max. 16 bar 232 psi

Water side max. 16 bar 232 psi

Water: 2 m/s 1,8 yd/s

Oil-water: 25 °C 77 °F

Temperature control unit

Temperature control units (option) are used forliquid temperature conditioning of moulds,barrels and screws.

Before operating the IMM its Safetyregulations and those of the temperaturecontrol unit must be observed without fail!

A temperature control unit may only beinstalled by a qualified electrician (accordingto DIN VDE 0105, or IEC 364)!

The installation, connection and commissioningof the temperature control unit are detailed inthe separate Operating Manual and in thecorresponding wiring diagram in the "Spares /Plans" chapter.

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



Chapter -4Page - 11


Air supply unit

Compressed air piping for the pneumaticsystem must be expertly laid and installted.Fittings, length and cross chapter have tomeet the requirements!

Work at the pneumatic system may only becarried out by a skilled pneumatictechnician!

If the pneumatic system is not relieved fromall pressure before work starts, there is arisk of explosive emptying with possibledamage or injury!

UNIFEED material feeder

The UNIFEED material feeder (option) replacesthe hopper so that production is not interruptedby filling the hopper.

It is especially suitable for feeding the followingpolymer granulates: PE-HD, PE-LD, PS, PA, PA+ GF, PP, ABS, POM, PPO.

The UNIFEED material feeder is well suited toconveying regrind and virgin materials together.The granule size, however, must no be largerthan 3 - 4 mm (0.12 - 0.16 inch).

123

45

1 - Pressure regulating knob2 - Condensate separator3 - Pressure gauge4 - Condensate reservoir5 - Drain screw

Setting• Turn pressure valve control knob (1)

clockwise until the desired pressure(min. 6 bar - max. 10 bar / min. 87 psi -max. 145 psi) is shown on the pressuregauge (3)

If the material feeder is located higher thanthe average body height, climbing aids andworking platforms which meet the legalsafety requirements must be used for filling!



Chapter -4Page - 12


• Move the climbing aid in front of the IMM

• Place the material feeder base plate onthe hopper support and fix with 5 bolts(in delivery kit)

• Mount the material feeder on the baseplate and attach it with knurled screws

• Line up the suction tube with themounting holes on the day bin (materialreservoir)

• Fit the air valve and proximity switch andconnect according to wiring diagram

• Position the proximity switch directly onthe perspex and adjust it with theadjusting screw so that the LED lights upwhen the tube is full and goes out whenthe tube is empty

• Attach the compressed air hose (ND19 mm / 0.75 inch ) to the connectingbranch and fasten with a hose clip

• The air hose must be laid so that anunrestricted air supply is guaranteed.Care must be taken not to kink or crushhoses

• The hose must be long enough to allowfor the movement of the injection unit

• The hose must be suitable for thesystem pressure (max. 7 bar - 101 psi)and the temperatures reached in use


The IMM may only be connected to a powersupply which corresponds in terms of currenttype, voltage and frequency to the data given onthe electrical specification plate.

The maschine can be connected to a powersupply with a frequency of 50 Hz or 60 Hz.

The PLUS- series is supplied in three differentvoltage variants.

a) Voltage 3~230/400 VoltThe mains voltage is determined according tothe norm IEC at 3~230/400Volt (+6 %, -10 %).In addition the machines can be operated with apower supply of 3~220/380 Volts or 3~240/415Volts within the above voltage variations. Aneutral conductor connector is essential here.

b) Voltage 3~230 VoltsA neutral conductor connector is not essentialhere.

c) Voltage 3~200Volts - 220 VoltsThe machine can be operated within the abovevoltage limits. A neutral conductor connector isnot essential here.



Chapter -4Page - 13

Electrical installation may only be carriedout by a qualified electrician (qualified to DINVDE 0105 or IEC 364 or equivalent)!

The electrical supply lines must be designedaccording to the specifications on thenameplate!

The currently valid local regulations onearthing and overload protection (overload,wrong polarity protection) in TN-, IT- or TTsupplies must be observed without fail bythe proprietor of the machine!

The protection for the phase conductors andthe neutral conductor (IT-supply) must bearranged to comply with the data on theelectrical specification plate!

Connection as "Cassical zerorising" (EN-conductor) must not be used. E-conductorand N-conductor (if used) must always beconnected separately!

Main connectorThe connection directly to the main switchThe correct phase sequence (righthand field) isto be noted here.

The main switch is further equipped with an N-switch contact leading to all-pole separation.

The cable feed is alternatively possible on twoPG 29 inlets on the side of the electric cabinet

1 - Lead without neutral

1T31T2

1T1

4 (L1, L2, L3, E)

b) , c)

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

1T11T2 N

1T3

a)

2 - Lead with neutral

Checking the direction of rotation of thehydraulic pump’s drive

Before switching on the IMM it must be ensuredthat:

• The hydraulic system is sealed, theelectrical cabinet is closed, the hydraulictank is filled and the hydraulic pump(s)has/have been primed

• The guarding and safety gates havebeen properly fitted and are closed

CautionThe pump will not work correctly if thedirection of rotation is wrong and the driveand the hydraulic pump will fail!

• Connect the supplies, as describedunder "Electrical equipment" paragraph



Chapter -4Page - 14


The hydraulic motor’s direction of rotationmay only be tested by a qualified electrician(qualified to DIN VDE 0105 or IEC 364 orequivalent)!

• Open the electrical cabinet

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

• Switch on the power supply (low voltagedistribution)

• The phase sensor must now indicate aright-hand (clockwise) field

• Switch off the power supply (low voltagedistribution) if the direction of rotation isnot correct and exchange two phase ofthe power connections 1L1, 1L2, and1L3 of the mains cable in the electricalcabinet

• Close the electrical cabinet

Finally start the hydraulic pump(s) in "Settingmode" and allow to run for a few secondswithout load in order to lubricate the pump(s).


A: PB2GB0FA.P65B: PB2DE0FA.P65E: 180202 / RuderG: 190202 / G. Krajnik


4.13 Mould mounting

Preparation

If the IMM has a robot interface (according toEuromap 12; VDMA) and the IMM is to be runwithout the robot, then the latter should beswitched off and the supplied dummy plug(430X1) must be inserted. Operation of the IMMwithout this linking out is not possible. Theinstallation of the links is detailed under"Interfaces". The interface is located on the sideof the electrical cabinet or in the rear middlepanel.

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

• Mould height and dimensions must suitthe IMM

• The sprue bush or hot runner radiusmust correspond to the IMM nozzleradius

• The centring mechanism must be thecorrect size for the boring in the nozzle(or moving) platen

• The length of the ejector bar and theejector stroke must be compared withthe IMM specification (see "TechnicalData" chapter)

• Check that the water fittings are the rightsize

• The mould should have been checkedfor binding, seizing, missing or looseparts and badly adjusted side actions

• Water and air connections should bemade to check for leakage

Danger! It must be ensured that no personsstand or linger under the suspended load!

The lifting gear should not be removed untilthe mould is bolted securely to both platensand this has been verified by authorisedpersonnel!

A: PB2GB0FA.P65B: PB2DE0FA.P65E: 180202 / Ruder




When the above points have been checked themould can be mounted. The following pointsshould now be observed and followed withoutfail:

• The mould must hang vertically from thelifting gear

• The mould halves must be preventedfrom sliding apart

• The mould clamps (mounting elementsfor the mould; not supplied as standardwith the IMM) must be the same heightas the thickness of the mould bolsters,as otherwise there is a risk of the mouldslipping

CautionThe number of mould clamps must beadequate for the opening force!

• Make sure the bolts are of the rightlength; at least 1.5 D. (D = diameters ofthread)

• Use proper washers

• The above points apply equally to themounting of a mould to platens with T-slots

Mould mounting

1 Switch on main switch

2 Press and release the emergency stopbuttons on the IMM and robot, if present;the "Test EMERGENCY STOP" errormessage will disappear

3 Turn on water supply from cooling watersystem to oil cooler

4 Open and close all safety gates (to testthe safety gate monitoring)

5 The hydraulic drive and at the same timethe oil pre-heating are switched on withthe "Hydraulic Start" key

6 After the control boots up the "Password - System" page will appear




7 Press the "Error messages" key; the"Error messages" page appears

The "Oil heating" fault symbol lights up

This error message disappearsautomatically as soon as the hydraulicoil comes up to operating temperature

See also the "Error messages" Section

in the "UNILOG B2 Users’ Manual"

8 Return to the "Password - System" pagewith the "Machine general" key

9 Log on to the control

10 Enter the password "1998"

11 Press the "ENTER" key

12 If further error messages are displayed,see the "UNILOG B2 Operators’Manual", "Alarm list" section to find outhow to clear them

Once all the errors are cleared and thehydraulic pump is started, mouldmounting can be continued

G

13 Mount mould on nozzle platen

13.1 Press the "Mould open" key and openthe mould

13.2 Bring the mould into the open clampingunit

13.3 Locate the mould in the nozzle platen’scentring mechanism

13.4 Position the mould square to the IMM’slateral axes

13.5 Attach the mould to the nozzle platenwith mould clamps; it is essential to usebolts of the correct length; at least 1,5 D(D = diameters of thread) must screwinto the IMM platen

The mould clamps (mounting elementsfor the mould; not supplied as standardwith the IMM) must be the same heightas the thickness of the mould bolsters,as otherwise there is a risk of the mouldslipping

13.6 Press the "Mould Close" key and closethe mould

-

/1

!9

,8

!9

ENTER





14 Log off from the control

To prevent unauthorised persons fromentering set values, the user must log offfrom the control unit after quitting thesetting mode!

14.1 Press the "Machine in general" key

14.2 Move the cursor with the arrow keys toinput field "N1". Enter a set value of "0"

14.3 Press the "ENTER" key

14 Fix mould to the moving platen

14.1 Press the "Mould Close" key and closethe mould

14.2 Fix the mould to the moving platen withmould clamps; make sure the bolts arethe correct length; see step 14.5

14.3 Remove lifting gear from mould

14.4 Remove the safety strap holding the twomould halves together

14.5 Connect the ejector coupling (mould tohydraulic ejector cylinder)

14.6 Press the "Mould open" key and crackthe mould open

14.7 Press the "Setting" key; this avoidsdamaging the mould on initial opening

14.8 Press the "Mould open" key and openthe mould

G

ENTER




4.14 Interface

The interfaces and sockets for peripheralequipment are located on the side of theelectrical cabinet (Option).

Details of installation, connection andcommissioning are to be found in theappropriate Operating manuals.

Before operating the IMM with peripheralequipment, its safety regulations and theoperating instructions of the peripheralequipment in question must be observedwithout fail!Electrical installation may only be carried

out by a qualified electrician (qualified to DINVDE 0105 or IEC 364 )!

For some peripheral equipment a dummy plugmust be used in the interface when the IMM isoperated without the peripheral equipment.

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

Before switching on the emergency stop buttonsshould be released by rotating a quarter turnclockwise and program selection switches set tothe required position.

The start impulse for automatic operation of aperipheral device is given by starting anautomatic cycle of the IMM.

Automatic operation is stopped by operating anemergency stop button or by switching the IMMoff or out of automatic mode.





4.15Checking safety devices

The safety devices can only fulfil their purpose iftheir faultless operation can be guaranteed.Therefore it is necessary to check the followingfor effective function before operation:

• Electrical closing interlock: Limitswitches securely fixed

• Hydraulic interlock: limit switch securelyfixed

• Mechanical scotch (Option): freemovement of swinging scotch (flag) onthe moving platen and the correctposition (teeth) of the stop rod

CautionIf a fault arises on the IMM which causes themechanical scotch to come into operation,Battenfeld Customer Service or theresponsible agent must be contacted!

• Purge guard: free movement andsecurely fixed limit switches

• Purge guard, safety grid and guarding:security of all fixing bolts andundamaged condition

4.16 Test run and interlock test

Operating and other personnel may onlystand in front of the IMM on the operator’sside during operation!

It is forbidden to stand on the IMM or reachinto the injection unit during operation!

Install required safety devices. The safetyregulations in the "Safety" chapter are to befollowed without fail!

• After electrical installation safety devicesare to be tested (e.g. earthingresistance)

• Check hydraulic lines and componentsfor leaks

• Check all visible fittings for security

• Close safety gates and check for properfitting

• Clear inside of IMM of all foreign bodies(forgotten tools, etc.)

• Set peripheral equipment to the startingposition, i.e. the position in which nodamage to it or to IMM components ispossible

• Turn on water supplyfrom cooling watersystem to oil cooler

• Check the function of the safety systems




CautionIt is essential to select "Setting" mode, orelse the test run may damage the mould!

Ejector movements may only be tested withthe mould open or else the mould may bedamaged!

Check the movements of the various units asfollows:

• Switch on main switch (to "1")

• Open and close the clamping unit’ssafety grid (to check the safety gridmonitoring)

• Switch on hydraulics ("Hydraulics start"key)

• Start the pump without load and run for afew seconds to make sure of adequatelubrication

• Press "Setting mode" key

• If the mould has been left in the "Mouldclosed" position after mould mounting,open it with the "Mould open" key

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





Structure and function

A: PB2GB0GA.P65B: PB2DE0GA.P65E: 180202 / RuderG: 190202 / G. Krajnik

Chapter - 5Page - 1

?

5.0 Structure and function

5.1 View of assemblies - PLUS

5.2 Clamping unit

5.3 Injection unit

5.4 Hydraulics

5.5 Pneumatics (option)

5.6 Electrics

5.7 Control unit

5.2 5.3

5.4

5.65.7

A: PB2GB0GA.P65B: PB2DE0GA.P65E: 180202 / Ruder


Chapter - 5Page - 2


?

5.2

5.3

5.5

5.5

5.4

5.6

5.7

5.1 View of assemblies - PLUS-V

5.2 Clamping unit

5.3 Injection unit

5.4 Hydraulics

5.5 Pneumatics

5.6 Electrics

5.7 Control unit



Chapter - 5Page - 3

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5.2 Clamping unit - PLUS

Technical specification

The clamping unit basically consists of aclamping platen (pos. 1) in a casting design withintegrated hydraulic ejector (pos. 2), a nozzleplaten (pos. 3) in the casting design with aclearance zone (pos. 4) which also serves as apurge guard for the injection assembly. Inaddition the guides for the piston rods on theclamping cylinder (pos. 5) are integrated in thenozzle platen.

The two clamping cylinders consist of cylinderpipe (pos. 6), piston rods (pos. 7), quick liftingcylinder piston (pos. 8), seal bush 8 (pos. 9)fixing nuts (pos. 10) and the slide plates (pos.11) for the clamping platens.

2 46

7

89310 111



Chapter - 5Page - 4


?

Description of functions:

The connection with the machine body isreached through the nozzle platen. Theclamping platen is equipped in accordance witha standard support, which takes the weight inthe machine body.

The slide plates of the clamping platen are tobe lubricated every 2500 operating hours.

The clamping force is applied by two clampingcylinders. Through the extremely stablestructure of the box-shaped clamping andnozzle platen an optimum distribution of theclamping force is acheived.

The quick lifting cylinder piston allows a quickclosing movement and also a sensitive mouldsafety device.

The clamping force build up is implemented viathe suface force of the piston rod, which isdesigned in such a way that the full clampingforce is acheived at a hydraulic pressure of 210bar (3045 psi). This clamping pressure, which ispurposefully kept at a low level, enables a longlife-span of the seals and guides in the guidebushing.

The piston rod is inserted into the nozzle platen.Special attention is paid to the distance to theseals, so as to ensure that the hydraulic sealsare not damaged or destroyed if the piston rodsare damaged during the mould mounting.

There is a void between the seals and theguides where oil leakage is collected and candrain away.

The ejector is designed as a double actioncylinder and has been integrated in the box-frame-construction of the clamping plate.

Mould mounting

The mould is fixed in the clamping unit fromabove with the appropiate lifting equipment. Themould is positioned in the nozzle platen bymeans of alignment (D= 110 f7, 4,33 inch).

The fastening can be carried out in threedifferent ways:

1. Directly screwing down at least twodiagonal threads per half mould, in themounting platen (M12, tightening torque70 Nm, 98ft lb)

2. Directly screwing through the mountingplaten by means of 4 cap head screwsM12 x 95 (tightening torque 70 Nm, 95 ft1b) in the designated clearance holes(D = 14; 0.55 inch)

3. A fastening with at least 2 mould clampsper mould half, which must be diagonallyalligned on each mounting platen.



Chapter - 5Page - 5

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Adjustment instructions for mould heightadjustment.

Ex works the minimal mould height is set at150 mm (5,9 inch). The mould height can beadjusted by the fixing nuts, so that the maximumopening stroke can be used to it’s full potential.To adjust the mould height proceed as follows:

1. Mark the intended area for the fixingnuts (pos 1) on the clamping platen

2. Remove the fastening screws (pos 2)

3. Unscrew the rear fixing nuts (pos 3) tothe end of the piston rod

4. Calculate the required number ofrotations of the fixing nuts. The screwthread has a gradient of 4 mm, whichdetermines the setting range:

If the result is not an even number, itmust be rounded up to the next evennumber

Set the adjustment of the fixing nuts

5. Unscrew the clamping platen (pos. 4)back to the stop on the fixing nuts. Verifythe alignment of the markings

6. Screw the rear fixings nuts (pos 3) to2 mm (0.08 inches) to the front fixingnuts and check the alignment of thefixing holes

7. Screw in the fastening screws andtighten (torque of 40 Nm; 54ft lb)

The long guiding movement of the piston rodsand the clamping platen on the piston rodensure that no platen parallelism errors occurdue to the mould height adjustment.

4

1

2

3



Chapter - 5Page - 6


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5. Mechanical scotch (Option):

The mechanical scotch prevents the accidentialclosing of the clamping unit by opening thesafety gate.

The main components are the toothed scotch-bar, which is fastened to the clamping platenand the pivoted stop, which is fastened to thenozzle platen.

By opening the safety gate the pivoted stop fallsonto the scotch bar because of it’s own weight.This activates a locking function which closesthe clamping unit and which prevents the mouldclosing.



Chapter - 5Page - 7

?

5.2 View of assemblies - PLUS-V


The main components of the clamping unit are anozzle platen (pos. 1) in the casting design, amould mounting platen (pos. 2) in the castingdesign with an integrated hydraulic ejector (pos.3) and the two guide tie-bars (pos. 4).

The two clamping cylinders consist of cylinderpipe (pos. 5), piston rods (pos. 6), quick liftingcylinder piston (pos. 7), seal bush (pos. 8) andthe fixing nuts (pos. 9).

1

2

3

4

5

8

7

6

9

4



Chapter - 5Page - 8


?

Description of functions PLUS V

The connection with the machine body isreached via the mould mounting platen.

The clamping force is applied by two clampingcylinders. Through the extremely stablestructure of the box-shaped mould mountingand nozzle platen an optimum distribution of theclamping force is acheived.

The quick lifting cylinder piston allows a quickclosing movement and also a sensitive mouldsafety device.

The clamping force build up is implemented viathe suface force of the piston rod, which isdesigned in such a way that the full clampingforce is acheived at a hydraulic pressure of210 bar (3045 psi). This clamping pressure,which is purposefully kept at a low level,enables a long life-span of the seals and guidesin the guide bushing.

The piston rod is inserted into the mouldmounting platen. Special attention is paid to thedistance to the seals, so as to ensure that thehydraulic seals are not damaged or destroyed ifthe piston rods are damaged during the mouldmounting. There is a void between the sealsand the guides where oil leakage is collectedand can drain away.

The ejector is designed as a double actioncylinder and has been integrated in the box-frame-construction of the mould mountingplaten.

Mould mounting PLUS V

The mould is introduced laterally or from thefront with the appropiate lifting equipment. Themould is positioned in the mould mountingplaten by means of alignment (D = 110 f7,4,33 inch).

The fastening can be carried out in threedifferent ways:

1. Directly screwing down at least twodiagonal threads per half mould, in themounting platen (M12, tightening torque70 Nm, 98ft 1b)

2. Directly screwing through the mountingplaten by means of 4 cap head screwsM12 x 95 (tightening torque 70 Nm, 95 ft1b) in the designated clearance holes(D = 14; 0.55 inch)

3. A fastening with at least 2 mould clampsper mould half, which must be diagonallyalligned on each mounting platen



Chapter - 5Page - 9

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Adjustment instructionsMould height adjustment PLUS V

3

4

2

1

Ex works the minimal mould height is set at200 mm (5,9 inch). The mould height can beadjusted by the fixing nuts, so that the maximumopening stroke can be used to it’s full potential.To adjust the mould height proceed as follows:

1. Mark the intended area for the fixingnuts (pos. 1) on the clamping platen

2. Remove the fastening screws (pos. 2)

3. Unscrew the rear fixing nuts (pos. 3) tothe end of the piston rod

4. Calculate the required number ofrotations of the fixing nuts. The screwthread has a gradient of 4 mm, whichdetermines the setting range:

If the result is not an even number, itmust be rounded up to the next evennumber

Set the adjustment of the fixing nuts

5. Unscrew the nozzle platen (pos. 4) backto the stop on the fixing nuts. Verify thealignment of the markings

6. Screw the rear fixings nuts (pos. 3) to2 mm (0.08 inches) to the front fixingnuts and ensure the alignment of thefixing holes

7. Screw in the fastening screws andtighten (torque of 40 Nm; 54ft lb)

The long guiding movement of the piston rodsand the nozzle platen on the piston rod and theadditional tie bars ensure that no platenparallelism errors occur due to the mould heightadjustment.

The opening and closing movements can onlybe triggered by a reversing injection unit. Theinjection unit must be reversed in the operatingmode "Manual" until the end of the t1 time"nozzle-removal-time".

In general the injection unit must always bereversed so far, so that a safe opening orclosing movement can be carried out.





?

Mechanical scotch PLUS V

The mechanical scotch prevents the accidentialclosing of the clamping unit by opening thesafety grid.

The main components are the toothed scotch-bar, which is fastened onto the clamping platenand the latch, which is fastened pivoted to themould mounting platen.

On opening the safety hood the latch locks thetoothed rack. This activates a locking functionwhich closes the clamping unit and whichprevents the mould closing.

The latch is monitored by the limit switch oneach opening-closing cycle of the safety grid.


A: PB2GB0HA.P65B: PB2DE0HA.P65E: 180202 / RuderG: 190202 / G. Krajnik


?

5.3 Injection unit


The injection unit consists of a plasticating unit(pos. 1), mounting for the plasticating unit (pos.2), fixing nuts for the screw barrel (pos. 3), thedrive unit for metering including hydraulic motor(pos. 4), cylinder block (pos. 5) with integratednozzle movement cylinders (pos. 6), injectioncylinder (pos. 7) and the linear guides.

48 5

6321 7

A: PB2GB0HA.P65B: PB2DE0HA.P65E: 180202 / Ruder




?

Description of functions:

The injection assembly is controlled on thelinear guides and the nozzle movementcylinders.

The nozzle movement cylinders are directlyintegrated on the clamping cylinder and aredouble acting hydraulic cylinders. The nozzlemovement cylinder is used to connect thenozzles to the mould and allows access to thenozzle in the rearmost position.

The screw is driven over a slow operatinghydraulic motor, which acts over a toothed beltdirectly on the injection cylinder piston. Duringmetering the injection piston is turned. With thisdesign the bearings, which must be made forthe thrust bearing of the screws, can be omitted.This function will be hydraulically carried out.The injection pistons are also used for thescrew coupling.

To ensure a long service life for the barrelheater bands, they should be checked whenhot at regular intervals, starting withcommissioning, for secure fitting.

Nozzle changing

Prerequisites:

1. Barrel purged empty

2. Heat the barrel up to the processingtemperature of the last used material

Working cycle

1. Drive the nozzle cylinder of the injectionunit back to the stop

2. Unplug and remove the nozzle heaterband

3. Unscrew the nozzle with a suitable ringspanner

4. Screw in new nozzle, while ensuring thatthe screw thread is lubricated with aheat resistant Molykote

5. Screw nozzle home but do not finallytighten

6. Fit nozzle heater band and plug it in

7. After heating the nozzle to operatingtemperature is should be finally tightened




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Adjustment instructions nozzle centre

The nozzle centre is set on the factory premisesand after transportation must be controlled, andif necessary adjusted,during commissioning.

According to the installation instructions themaschine must be horizontally installed andthen the injection unit must be adjustedaccording to the following instructions.

1. Measure the centre nozzle deviationagainst the central diameter bothvertically and horizontally

2. If a horizontal deviation is detected, itcan be corrected by adjusting the guiderails (pos. 1)

3. If a vertical deviation is detected, it mustbe moved into the prescribed position bythe adjusting screws (pos. 2)

4. Fix nut (pos. 3) by lock nut

Finally carry out a control measurement.If the measurement shows a larger deviationthan 0.2 mm the injection unit must be newlyadjusted.

Changing the tooth belt and pretension

3

2

1

136

254

1. Disconnect screws and move theinjection cylinder to the rear limit position

2. Loosen fastening screws (pos. 1, 3x)and tighten by hand, so that no gap canoccur between the guide plates and thehydraulic motor

3. Move the hydraulic motor to the upperlimit position by means of an eccentricdisc (pos. 3)

4. Remove the distance screws (pos. 5 4x)and drag the guide plates (pos. 4) fromthe pulley

5. Remove pulley (pos. 6) from schaft





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6. Lay toothed belt over pulley and fit onshaft, so that the toothed belt also slidesover the upper pulley

7. Install guide plate with spacer (pos. 5)

8. Preload the toothed belt (note point 2) bymeans of an excentric plate (pos. 3).Indentation pressure 140 N on thecentral toothed belt, indentation depth2 mm (0.08 inches)

9. Tighten the hydraulic motor withfastening screws (pos. 1, 3x) (maxtightening torque 80 Nm, 110 ft lb)

Changing the screws and screw barrel.

Prerequisites:

1. Barrel purged empty

2. Heat up the screw barrel to thepreviously chosen temperature of thelast used material, disconnect heaterbands and sensors

Working cycle:

1. Drive carriage cylinders back to rear limitposition

2. Drive injection cylinder forward to stop

3. Dissconnect the maschine from thepower supply by switching off mainswitch

4. Dismantle safety guard on the screwbarrel

5. Loosen screw coupling (pos. 1, 2 x M6)

6. Dissconnect washer from thrust piece(pos. 2) and remove feather key (pos. 3)

7. Loosen screw barrel nuts (pos. 4) andunscrew from thread

8. Pull screw barrel away towards thenozzle platen and move in and out inupward direction

9. Disconnect hoses for traverse cooling

10. Fit a new screw barrel and tighten withnuts

11. Screw coupling

12. Install safety guards

13. Install heater bands, sensors and hoses

14. Turn on the maschine with the mainswitch and heat up to materialtemperature

21 34




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Installation instructions for vertical injection uni.

Prerequisites:

1. Disconnect heater bands and sensors

2. Crane or appropiate lifting equipment

Working cycle:

1. Dismantle guard from above

2. Dismantle material conveyor, reel ormaterial hopper

3. Install base plate on hydraulic block

4. Fasten lifiting device (2 x M24) and hangcrane under tension

5*. Unscrew grub screw (4 x M20) to adjustheight

6*. Loosen screws (4 x M20) on clampingpiece and remove horizontally

7. Lift the injection unit with crane, swivelby 90° and screw in the fixing screws (2x M12) in the connecting tube





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8. Lift the injection unit over the clampingunit, lower and tighten

9. Dismantle lifting device

The safety gate may not be openedbeforehand.

10**. Install all guarding panels and covers

11. Install material conveyors, reels ormaterial hoppers on the base plate

12. Connect heater bands and sensors

* Only with the option of conversion kit** Dependant on conversion kit




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Conversion instructions for horizontal injection unit

Prerequisites::

1. Disconnect heater bands and sensors

2. Crane or appropiate lifting equipment

Working cycle:

1. Open up the nozzle platen completelyand move the injection unit into the topposition

The safety gate however remains closed

2. Remove the base plate with materialconveyors, reels or material hoppersfrom the screw barrel

3. Unscrew guard from above

4. Fasten lifiting device in the injection unitwith crane hooks (2 x M24) and screw infixing screws (2 x M12) in the connectingtube

5. Dismantle injection unit (4 x M20) and liftwith the crane





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6. Open the safety gate and check if theclamping piece is fastened onto the tiebars

7. Remove coverplate

8. Move the injection unit in position overthe machine body, unscrew the fixingscrew and swivel the injection unit by90° (so that it is in a horizontal position)

9. Connect the injection unit onto theclamping piece and tighten (4 x M20)

10. Adjust the height of the screws (4 x M20)by screwing in nuts to the stop

Do not tighten11. Dismantle lifting device

12. Loosen clamping piece on tie bars andset to the required height according tothe table by adjusting the height of thescrews

13. Tighten clamping piece

Fix the height of the screws using the nuts.Only adjust the height of the screws if theclamping piece is loose.

14. Install material conveyors, reels ormaterial hoppers on the screw barrel


A: PB2GB0IA.P65B: PB2DE0IA.P65E: 180202 / RuderG: 180202 / G. Krajnik


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5.4 Hydraulics

Pump unit

The electromotor, which is in permanentoperation, sits on the motor-pump-suspension.This drives the hydraulic pressure pump overthe coupling. The hydraulic pressure pump is avariable volume pump which is connected to thecentral hydraulic block by means of a hoseassembly.

The maximum system pressure amounts to210 bar (3045 psi).

Oil tank

The oil tank is a fixed component of themaschine body and equipped with a filter alongwith a venting filter and an oil level indicator.The control system indicates if oil levels are toolow. In this case the oil must be refilled to themarked level on the oil indicator.

In order to thoroughly clean the oil tank the lidof the tank can be removed by looseing somescrews in the fitting.

Oil filtering

To improve the reliability and the longevity of thehydraulic components and seals, the hydraulicsystem is equppied with a backflow filter, whichis integrated into the oil tank.

The backflow filter is situated on the reverseside of the maschine below the central hydraulicblock and is equipped with an electriccontamination indicator.

An error message , in the form of a symbol, isdisplayed on the control panel if the filterbecomes comtaminated. In case this erroroccurs the filter element must be changedimmediately.

To ensure trouble free operation and longservice life of the maschine, only originalfilter elements may be used.(Hydac 0165R010BN/HC; article no. MB628)

Oil cooler

An oil-suction-cooler, which lies in the oil tank,ensures adequate cooling of the hydraulic oil.It is essential to pay attention to the watersupply, to ensure it does not becomecontaminated. In this case a water filter must befitted in the supply to protect the operation ofthe cooling water valve.

This valve is inserted at the water supply andonly takes as much water as is necessary tocool the oil.

Reducing water flow rate does not save anywater.

A: PB2GB0IA.P65B: PB2DE0IA.P65E: 180202 / Ruder




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Hydraulic oil preheating

As soon as the hydraulic pump is started thecold hydraulic oil is automatically preheated to atemperature of 40 °C (104 °F).

While the oil temperature is below this value,the screen shows an error message and theIMM can not be moved. On reaching the 40 °C(104 °F) mark the oil preheating switches offand the IMM is ready for use.

While the IMM is running the oil temperature isregulated to a constant 45 °C (113 °F). This isachieved by opening and closing the coolingwater valve on the oil cooler.

If the oil temperature exceeds 60 °C (140 °F) anerror message is shown on the screen. If thetemperature climbs over 65 °C (149 °F), thecontrol switches the IMM hydraulics off.

The reason for the oil’s overheating must beestablished and the fault remedied (e.g. watersupply failure, cooling water shut-off valve on oilcooler closed).

After operating the emergency stop button oncethe hydraulics can be restarted. In this way thehydraulic oil is cooled. No manner ofmovements (from the clamping and injectionunit) are possible during this phase.

Hydraulic core puller

The hydraulic core puller (option) consists of abase plate on which the required hydraulicvalves are installed and which includes the userconnections (2 x R3/8" - AD/8S).

The hose assemblies and fittings belonging tothe mould’s core puller cylinder(s) are notincluded with the IMM.

It should also be noted that the available systempressure is 210 bar (3045 psi). All connectionsand fittings must be able to withstand thispressure!

Hydraulic core pullers may be connectedand put into operation only by a hydraulicsexpert. The safety regulations in the "Safety"section must be followed without fail!




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Control and display

System pressure (M)

The hydraulic system pressure is shown on apressure gauge on the rear side of themaschine.

Back pressure (SPA)

On the rear of the maschine is the connectionfor the hydraulic back pressure. By convertingthe pressure gauge to the SPA connection theback pressure can be read during the meteringphase.

Oil level indicator

The oil level gauge is on the right front side ofthe tank. If the oil level is too low the hydraulicoil is to be filled (see chapter 7 "Maintenance").The oil level must be monitored daily to avoidany errors in the production processes.

Oil temperature

The oil temperature is measured in the oil tank.This temperature is indicated on the screen ofthe maschine control unit to the operatingpersonnel.

Setting the variable displacementpump

With a preselected pressure of approximately70 bar (1015) and a preselected volume ofapproximately 50 % the flow contoller of thevariable volume pump is set at ∆ p with themovement "Nozzle backward". The connectionsPP (pressure prior to the flow restrictor) and M(pressure after the flow restrictor) are used as ameasuring point on the control block.

The measurment should be carried out with thesame pressure transducer and with pendinghydraulic pressure.

10 bar (145psi) ∆ p are set on the flow controllerof the pump.

All pressure and speed settings are taken at anoil temperature of 45 °C (113 °F).





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Proportional valve amplifier

P1 Ramp time

P2 Sensitivity

P3 Zero point

P4 Dither frequency

St 1 Main terminals

LED Display UB

Set the proportional valve amplifier forspeed (B. No:. 0.811.405.143; article No.:SG696).

The speed setting is controlled by a proportionalspeed valve. The command to the valve iscontrolled by the proportional amplifier.

The speed setting of the amplifier must beprogrammed in the following order:

a) Do not adjust the potentiometer "Dither"= Manfacturer’s setting)

b) To move the "metering" preselect thespeed to 20 %

c) Activate the movement "metering" andset the potentiometer "P3 - Zero point",so that the following rotational speed isreached at a preselection of 20 %

Standard hydraulic motor OMS 80 ->screw speed 84 rpm (hydraulic motorscrew speed 92 rpm)

Special hydraulic motor OMS 100 ->screw speed 66 rpm (hydraulic motorscrew speed 72 rpm)

d) To move the "metering" preselect thespeed to 100 %

e) Activate the movement "Metering" andset the maximum screw speed with thepotentiometer "P2 - senstivity"

Standard hydraulic motor OMS 80 ->screw speed 420 rpm (hydraulic motorscrew speed 462 rpm)

Special hydraulic motor OMS 100 ->screw speed 330 rpm (hydraulic motorscrew speed 363 rpm)




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f) Repeat setting steps b, c, d, until thesettings are correct

g) Setting potentiometer "P1 - ramp time"to 0 %

(Rotate clockwise to the stop = 10 msec= Manfactutrer’s setting)

Setting propotional valve amplifier forpressure (B. Nr.: 0.811.405.144; part nr.:SG335)

The pressure setting is controlled by aproportional pressure limiting valve. Thecommand to the valve is controlled by theproportional amplifier.

The pressure setting of the amplifier must beprogrammed in the following order:

a) Do not adjust the potentiometer =Manfacturer’s setting)

b) To move the "Nozzle back" preselect thespeed to 100 %

c) To move the "Nozzle back" preselect thepressure to 10 %

d) Activate the movement "Nozzle back"and set a pressure of 21 bar (304,5 psi)with the potentiometer "P3 - Zero point"at the measuring point MPS

e) To move the "Nozzle back" preselect thepressure at 95 %

f) Activate the movement "Nozzle back"and set the pressure from 200 bar (2893psi) with the potentiometer "P2 -sensitivity." Maximum system pressureat 100 % is 210 bar (3045 psi)

Maximum pressure setting variablesetting volume pump

Adjustment is only necessary if 210 bar isnot punched on the name plate of the pumpat DR.

a) For the "Nozzle back" movementpreselect the pressure at 100 % and thespeed at 70 %

b) Activate the movement "Nozzle back"and set the pressure at 220 bar (3190psi) with the potentiometer "P2 -senstivity"

c) Activate the movement "Nozzle back"and set the pressure to 210 bar(3045psi) on the maximum pressurecontroller of the pump

d) Repeat the setting proportional valveamplifier for pressure





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5.5 Pneumatics

2

3

4

5

6

7

8

9

10

11

12

1

UNIFEED Material Feeder

Scope

The UNIFEED material feeder (option) isdesigned for use on plastics processingmachinery and is installed directly on the screwbarrel instead of the hopper.

The material feeder is highly reliable as it hasno moving parts and it is easy both to use andto service.

The following granular polymers can beconveyed by UNIFFED: PE-HD, PE-LD, PS, PA,PA + GF, PP, ABS, POM, PPO.


If the material level falls below the capacitiveproximity switch (6) during metering, thepneumatic valve (2) opens. Compressed air isblown into the venturi tube (11) through the airjet (9) generating a partial vacuum whichextends as far as the suction chamber (10) andthe feed tube (4).

This vacuum sucks a granule - air mixturethrough the suction tube (5) and connectinghose (1) into the feed tube (4). A primary filter(8) separates the granules from the conveyingair.

Dust is then removed from the conveying air inthe secondary filter (12) before the is ventedfrom the material feeder.




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When the material level once again reaches theproximity switch, the air valve is closed, the airflow stops and the conveying cycle is finished.

At the end of every conveying cycle a smallvolume of compressed air is fed in pulses to thesuction chamber (10), thereby cleaning thematerial dust automatically from the primaryfilter.

Processing regrind

The UNIFEED material feeder is well suited toconveying regrind and virgin materials together.The granule size must no be larger than 3 - 4mm (0.12 - 0.06 inch).

The higher proportion of dust will lead to heavierloading of the filter, so that shorter cleaningintervals must be allowed for.

Pneumatic core puller

The pneumatic core puller (option) consists ofan electrically actuated 4/2 pneumatic valve andall the consumer connections for a 6 mm boreplastic pipe NW 6 (0.24 inches).

The pneumatic core puller is located on thelefthand side of the machine well. Theconnection to the mould’s core puller cylinder isnot supplied with the IMM.

It should be noted that the compressed air usedshould be dried and lubricated and limited to apneumatic pressure of 6 bar (87 psi). Allconnections and fittings must be able towithstand this pressure!





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Figure: PV0008.TIF

7

6

1 2

3

45

Pneumatic saftey hood (PLUS - V)

The pneumatic saftey gate consists of aplexiglass cover (pos. 1), an electronicallymonitired saftey bar (pos. 2), two pneumaticoperating lifting cylinders (pos. 3), two checkvalves (pos. 4), two electronically operatedpneumatic valves (pos. 5) and two manuallyadjustable flow control valves (pos. 6, 7).

The limit position cushioning may be set bymeans of the adjusting screws at the liftingcylinder.

The opening and closing speed can be setusing throttle valves.

To prevent the saftey gate from lowering twocheck valves have been installed.

According to its positon, the saftey gate can beopened or closed by pressing the "Cycle start"switch on the operator panel.


A: PB2GB0KA.P65B: PB2DE0KA.P65E: 180202 / RuderG: 180202 / G. Krajnik


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5.6 Electrics

Electric drive

The pump unit is driven by a three phaseasynchronous motor.

The drive motor is coupled directly to thehydraulic pump and connected to suit theoperating voltage.

When connected correctly (the phase sequencemust give a righthand field, see "Transport -Installation" section) the drive motor will run left(seen from the D-end).

D - End: Drive end

N - End: Non-drive end (fan end)

CautionService and connection work on the terminalrail may only be carried out by an authorisedelectrician!

Switch cabinet

The electrical cabinet is easily accessed on thefront of the IMM and contains most of theelectrical components necessary for operation.

Control cabinet front view

1 Error lamp

2 Main isolator

3 Control panel

4 EMERGENCY STOP

5 Floppy

6 Printer socket

7 Socket support

8 Lock

1

2

3

4

6

5

7

8

8

A: PB2GB0KA.P65B: PB2DE0KA.P65E: 180202 / Ruder




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Control cabinet side view

1 Error lamp

2 Main isolator

3 Shot counter

4 Specifiction plate

5 Socket support

6 Point of main incoming supply

Control cabinet rear view

1 Reserve

2 Socket band heater zone 2

3 Socket band heater zone 1

4 Socket band heater nozzle

5 Output cable sensor zone 2

6 Output cable sensor zone 1

7 Output cable sensor nozzle (option)

8 Cable output

1 2 3 4 5 6 7

8

1

2

3

4

5

6




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Control panel

The control panel is divided into:

• A back-lit graphics-capable LCD screenwith 128 x 240 pixels

• Function keys for selecting the variousfunctions

• Cursor keys for moving the cursor in allfour directions within the screen, and the"Previous page" key which can be usedto go from page to page through a menu

5.7 Control unit UNILOG B2

General information

UNILOG B2 meets the requirements of an easyto see control. The clamp and injection units aredriven by an optimised control. Set value entryusing pictograms and quick function selectionsenable simple operation and universalapplication anywhere in the world.

Only a few pages are needed for thediagrammatic representation of the injectionmoulding process. They can be called updirectly via function keys. Assigning accesslevels with a password system ensures reliableoperation appropriate to the expertise of theuser.

For process evaluation a quality table and good/ bad part discrimination are provided.Reproducible setting is guaranteed by datastorage on ordinary floppy disks.





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• Numerical keypad with the "Enter", "C"(clear), "-" (minus) and "." decimal pointkeys

• Main machine function keys

• 16 function keys for moving the variousmachine parts

Using symbols for input and display reduces thenumber of menu pages and gives a rapidprocess overview. Arrangement andorganisation of the symbols promote intuitiveoperation. Only 3 graphic elements are used forinput and display.

Rectangular fields indicate actual valuedisplays, rectangles with triangular pointssymbolise set value entries. Program selectionsare represented by rectangles with solidtriangular points.

Injection unit

The arrangement of the strokes and speeds forthe injection phase is self-explanatory. Fourstroke points can be entered. The profileentered is interpolated to suit the characteristicsof the hydraulics. The actual values for screwstroke, injection time and pressure are shown inrectangular fields.

Holding pressure

The holding pressure profile is entered with 3profile points. The entry and display of holdingpressure time and cooling time complete thedisplay.

Quality table

An important aid in production monitoring anddocumentation is the quality table. Any four of36 parameters can be saved and monitoredover the last 50 cycles. Any monitoring channelcan be selected to control a discrimination flap.




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Disk drive / LPT printer port

Customer data can be saved using a 3 1/2"floppy disk drive. A parallel printer port isprovided for a printout of these data.

Control unit

The various components of the control are:

The backboard

The standard version of the backboard has 12slots and a 3 V / 950 mAh buffer battery. It ismounted on a standard top-hat rail.

The PS 465 power supply

The power supply provides power to the wholecontrol system. The output is 18-30 VDC.Operational status is indicated by 4 light diodes.

The IF260 processor with IF672 plug-inmodule

The 32-bit processor undertakes the control’scommunication with the terminal and theregulation and interpretation of the PLCprogram. On the plug-in module are an RS-232interface and 2 CAN interfaces.

The AM055 analog module

This module converts the analog signals intodigital signals and vice versa. It has 5 analoginputs and 3 analog outputs. The power supplyfor the stroke transducers is also incorporatedhere.

The AT660 temperature recording card

This card enables connection of 8 Fe-Cotemperature sensors.

The DI475 input module

Connection of 16 digital 24 VDC signals in 4groups. The status of the digital inputs isindicated by LEDs. Potential separationbetween groups and to control. Switchingthreshold in low range <5 V, in switchover range5 to 15 V and in high range >15 V.

The DO480 output module

This module switches 16 digital 24 VDC loads in2 groups. The maximum loads are 2 A on asingle output, 12 A on a group and 24 A on thewhole module. The status of the digital outputsis indicated by status LEDs.





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Operation

A: PB2GB0LA.P65B: PB2DE0LA.P65E: 180202 / RuderG: 180202 / G. Krajnik

Chapter - 6Page - 1

0

6.0 Operation


Due to various influences we recommendentrusting Battenfeld staff with thecommissioning of the plant. This should not onlybe done for reasons of warranty but, at thesame time:

• The IMM can be checked for anytransport damage or installation andconnection faults

• To instruct the operating personnel

• Additional advice on operation,maintenance and service can be passedon

6.2 Commissioning

• Observe the operating manual and inparticular the safety regulations in the"Safety" chapter

• Unload, transport, install and level theIMM as described in the "Transport -Installation" chapter

• Prepare the hydraulic unit as describedin the "Transport - Installation" chapter

• Prepare the water system as describedin the "Transport - Installation" chapter

• Turn on water supply from cooling watersystem to oil cooler

• Prepare the pneumatic unit as describedin the "Transport - Installation" chapter

• Open the air supply from thecompressed air system to the air supplyunit (option), UNIFEED material feeder(option), mechanical scotch (option)

• Prepare the electrical unit as describedin the "Transport - Installation" chapter

• Switch on the power supply (low voltagedistribution)

• Ensure that there are no highlycombustable and explosive air mixturesnear the screw barrel heating

• Lubricate lubrication points, asdescribed in the "Transport - Installation"chapter

• Switch on hydraulics ("Hydraulics start"key)

The standard IMM has an oil preheatingsystem, and can not be run until thehydraulic oil’s operating temperature hasbeen reached (after approx. 15 min.)

• Clear any error messages which appear(see "UNILOG B2 User’s Manual, Alarmlist" chapter)

• Mount the mould as described in the"Transport - Installation" chapter and setthe clamping force and the mouldmounting height

• Connect the peripheral equipment(option) as described in the "Transport -Installation" chapter

A: PB2GB0LA.P65B: PB2DE0LA.P65E: 180202 / Ruder


Chapter - 6Page - 2

Operation0

• Check the safety device as described inthe "Transport - Installation" chapter

• Open and close the safety grid andpurge guard (to test the safety gridmonitoring circuit)

• Mount the mould as described in the"Transport - Installation" Chapter and setthe clamping force and the mouldmounting height

• Connect the peripheral equipment(option) as described in the "Transport -Installation" chapter


• Open and close the safety grid andpurge guard (to test the safety gridmonitoring circuit)

It is forbidden to stand on the IMM or reachinto the injection unit during operation!

• Carry out the test run and interlock testas described in the "Transport -Installation" chapter

• Carry out the test run with / withoutmaterial as described in this chapter

• Select the operating mode and start theIMM

6.3 Starting the IMM afterEMERGENCY STOP

The emergency stop button is a safety switchfor shutting the machine down quickly. If it hasbeen operated it must be released, after thefault or the reason for the external emergancyshutdown (peripheral equipment e.g robot) hasbeen cleared, by rotating in the direction of thearrow. Then the IMM is switched on again asdescribed in the "Operating" paragraph and, ifnecessary, the mould cleared of the moulding bymeans of the ejector.

The starting position of the IMM is: Mould fullyopen, ejector, nozzle and screw back, corepuller (if present) moved out.

6.4 Test run without material

After after commission or changing the mould,the movements of the various units should betested before running a few manual cycles witha mould mounted.

The safety regulations in the "Safety"chapter are to be followed without fail!

1 Check whether the electrical cabinet,safety guards and safety gates havebeen properly installed or closed

2 Clear inside of IMM of all foreign bodies(forgotten tools, etc.)

3 Switch on the power supply (low voltagedistribution) - commissioning only

Operation


Chapter - 6Page - 3

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4 Switch on main switch

5 Release the emergency stop buttons onthe IMM by rotating a quarter turnclockwise

6 Open the water supply from the coolingsystem to the individual users (oil cooler,cooling water flow control, etc.) -commissioning only

7 Open the air supply from thecompressed air system to the air supplyunit (option), UNIFEED material feeder(option), mechanical scotch (option) -commissioning only

8 Check the safety device as described inthe "Transport - Installation" chapter

9 Open and close all safety gates (to testthe safety gate monitoring)

Press the "Open safety grid" and "Closesafety grid" keys in case of a power-operated safety grid (option)

10 Switch on hydraulics ("Hydraulics start"key)

This starts the oil preheating at the sametime. You now have to wait until thehydraulic oil is heated up to a minimumof 40 °C (104 °F).

Start the pump without load and run for afew seconds to make sure of adequatelubrication

Before operating the IMM the safetyregulations in the operating manual(s) of anyperipheral equipment must be followedwithout fail!

11 Commission peripheral equipment(option) according to the operatingmanuals and set them to the startingposition, i.e. the position in which nodamage to it or to IMM components ispossible

12 Clear any error messages which appear(see "UNILOG B2 User’s Manual, Alarmlist" chapter)

13 Press the "Manual" key

14 Log on to control (Screen page"Password-System")

Enter password in input field "N1"

15 Press the "ENTER" key



Chapter - 6Page - 4

Operation0

Set the set values for "Injection", "Lockingforce" and "Ejector" as low as possible foran acceptable injection cycle. Otherwiseforces may be present when opening themould which can possibly exceed the limitrange of the clamping elements!

16 Enter the set values for the injectioncycle on the appropriate pages

The set values for "Injection" are to beset as low as possible for an respectableinjection cycle. Otherwise the mould canpossibly be overloaded. When openingthe mould the chucking power can beexceeded

For moulds with a smaller base theejector force may exceed the retentionforce of the clamping elements whichwill cause the mould to disengage

Fire hazard! No smoking! Make sure thatthere are no flammable liquids, open flames,etc. nearby the barrel heating!

17 Remove all materials, liquids andobjects which should not be near theinjection unit

18 Press "Heating on" key. (Switches onbarrel heating)

19 Bring the IMM to the following startposition:

- Mould open

- Ejector back

Operation


Chapter - 6Page - 5

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- Nozzle back

- Screw back

- Core puller out (option)

20 Press "Automatic" key

21 Press "Machine general" key (twice ifnecessary)

Operating and other personnel may onlystand in front of the IMM on the operator’sside during operation!

22 Enter a set value of "0" in entry field N1(Select "Automatic" mode) and confirmwith the "ENTER" key

23 Press "Mould close" key; an automaticcycle is started

Up to size 2700 the "Semiautomatic 1"and "Semiautomatic 2" modes arestarted by closing the the safety grid(option)

In case of power-operated safety gridson the clamping unit, these grids will beopened automatically at end of the cyclein the "Semiautomatic 1 andSemiautomatic 2" operating mode.

During the test run, listen for anyunusual noises and check the function ofthe safety grids

The "Fully automatic", "Semiautomatic1" and "Semiautomatic 2" modes areinterrupted by pressing the "Manual" keyor an emergency stop button

Any leaks which possibly occur duringthe first few hours of operation canusually be cured simply by tightening thefittings



Chapter - 6Page - 6

Operation0

6.5 Filling the material hopper

• Make sure that the main switch isswitched OFF and secured againstunauthorised reconnection

If the material hopper, the material feeder orthe stuffing device are located higher thanthe average body height, climbing aids andworking platforms which meet the legalsafety requirements must be used for filling!

• Move the climbing aid in front of the IMM

• Clean the material hopper and check forforeign particles. For this reason the useof open material bags should be avoided

Follow the plastic manufacturers’instructions!

When processing plastics which give rise toharmful gases dusts or vapours, theoperator has a duty to provide suitableextraction for the protection of operatingpersonnel!

CautionThe operator has a duty to ensure no foreignbodies enter the material hopper of barrelthroat!

• Swing material hopper to mid position

• Fill in material

• Swing material hopper above the feedthroat of the screw barrel

• Remove climbing aid from the workingarea of the IMM

Operation


Chapter - 6Page - 7

0

6.6 Test run with material


• Prepare IMM as described in chapter"Test run without material", steps 1 to 3

• Fill material as described in chapter"Filling the material hopper"

• Prepare IMM as described in chapter"Test run without material", steps 4 to 18


• Open mould; move ejector and nozzleback; move core puller back, ifnecessary

• Drive screw forward ("Injection" key)

• Press "Metering" key and carry out amanual metering process

• Press "Automatic" key

• Press "Machine general" key (twice ifnecessary)

• Enter a set value of "1" or "2" in entryfield N1 (Selects "Semiautomatic 1" or"Semiautomatic 2" program) and confirmwith "ENTER"

• Depending on the program selectioneither press the "Close mould" key orclose the safety grid (see step 24 in the"Test run without material" section) tostart the IMM

In this way several cycles are run.

Thus the movements of the various units, thesettings and the quality of the mouldings arechecked. Depending on the application,appropriate corrections are made to the variousset values in order to achieve the qualityrequired for the moulding.

Once all the set values have been entered theycan be saved to avoid unnecessary data loss.



Chapter - 6Page - 8

Operation0

For additional security the set values completewith mould number and part number should beprinted out and placed in the Operating Manual.

For procedure see the "UNILOG B2 User’sManual" chapter 17 "File management".

To prevent unauthorised persons from setvalue input, the user must log off from thecontrol unit after quitting the setting mode!

G

• Press the "Machine in general" key

• Move the cursor with the arrow keys toinput field "N1"

• Enter an invalid password, e.g. "0" (thisprevents set values from being entered)

ENTER

• Press the "ENTER" key

6.7 Operation

The operation of the IMM does not differ fromthe procedure described in chapter "Test runwithout material" and the procedures describedin this chapter.

After each shutdown and before each start-up of the IMM, the safety devices have to bechecked after switching on the main isolatoras described in the "Transport - Installation"chapter!


For the first few hours in which the IMM is usedunder production conditions, the followingshould be monitored in particular:

• The hydraulic oil temperature

The optimum working temperature of thehydraulic oil is between 45 °C and 50 °C(113 °F and 122 °F)

The current oil temperature is displayedon page 2 of the screen page"Temperature control zones" in theactual value field "T12"

Operation


Chapter - 6Page - 9

0

This is called up by pressing the"Temperature control zones" functionkey twice

• The proper fit of the fastening nuts

The fastening screws of the fasteningnuts may loosen due to the constantlychanging loads. After the first 100running hours they must be tightenedand checked for security

• The screw barrel heater bands

The screw barrel heater bands must bechecked for security at operatingtemperatures every 2500 running hours

Periodical checks should be performed duringoperation at regular intervals and according tothe procedure described in the "Maintenance"chapter.

Visible defects are to be remedied immediately.

Remedy damage immediately. Hydraulic oilsescaping at high pressure can cause severeinjuries and fires!

This applies especially to hydraulic fittings andhose assemblies.

6.8 Shutting the IMM down

1 Press the "Manual" key

2 Set peripheral equipment to the startingposition (option) and switch off anyperipheral equipment according to itsoperating manual

3 Switch off the UNIFEED material feeder(option)

4 Pull the hopper away from the feedthroat of the barrel

5 Move the core pullers out of the mould ifappropriate

6 Move the clamping platen to the startingposition (Mould open). If necessaryremove the moulding(s) from the mouldusing the ejector

Burning hazard! Do not touch escapingmaterial!

7 Swing the material hopper from the inletarea of the screw barrel to the midposition

8 Press the "Injection unit back" key

9 Place an appropriate reservoir in front ofthe nozzle and purge the remainingmaterial at short intervals

10 Switch off hydraulics ("Hydraulics Stop"key)

11 Switch off the heater ("Heater off" key)

H H




Operation0

12 Close and relief the cooling water supply(add rust preventing agent, ifappropriate) from pressure

13 Close and relieve the compressed airsystem (option) from pressure

14 Turn off the main switch and use apadlock to prevent accidentalreconnection. The main switch shouldbe operated whenever possible withoutapplied load

Extended shutdown

1 Shut down the IMM as described in"Shutting the IMM down"

Swing the material hopper to theemptying position and fill the remainingmaterial into an appropriate container

2 First free the screw barrel and the screwfrom the remaining melt and purge outwith polyethylene

3 Depending on the material to beprocessed, the nozzle and the screwmust be removed and cleaned

4 Preserve the cavities of the mouldaccording to the manufacturer’sinstructions

5 Treat all bare parts with a corrosioninhibitor

6 Empty the cooling water system, blowout with compressed air and treat with acorrosion inhibitor

6.9 Shut down procedure

1 Shut down the IMM as described in"Shutting the IMM down", steps 1 to 9

2 Preserve the cavities of the mouldaccording to the manufacturer’sinstructions

3 Dismantling the mould

In this paragraph the dismantling of amould fastened with mould clamps isdescribed

3.1 Press the "Mould close" key and closethe mould

The mould may only be dismantled by anauthorised skilled technician!

3.2 Disconnect the ejector coupling (mould /hydraulic ejector cylinder)

Operation



0

Burning hazard if touched. At mouldtemperatures above 60 °C (140 °F) wearappropriate protective clothing!

3.3 Let the mould cool down to a safetemperature (material dependent)

3.4 Prepare the mould for dismantling(Disconnect cooling hoses, heatingcables etc)

3.5 Attach the safety strap to prevent thetwo mould halves from sliding apart

The safe working load of the lifting gearmust equal or exceed the weight of themould!

3.6 Attach sling to the mould

3.7 Slightly tension the lifting equipment

3.8 Press the "Setting" key

3.9 Loosen the mounting elements of themould on the clamping platen

3.10 Open the mould

3.11 Undo the mounting elements of themould on the nozzle platen

3.12 Remove them from the centringmechanism in the nozzle platen

Danger ! It must be ensured that no personsstand or linger under the suspended load!

3.13 Lift the mould horizontally out of theopened clamping unit

3.14 Preserve the mould according to themanufacturer’s instructions and preparefor storage

4 Let the heating elements and theirguardings, mould temperature controlunits and their flow and return lines andtheir fittings and mounting elements cooldown to a safe temperature

5 Move the piston rods of the hydrauliccylinders in the setting mode as far aspossible into the hydraulic cylinder toprotect them from corrosion




Operation0

In case of a possible disassembly,release any remaining pressure bycarefully loosening (but not completelyundoing) the appropriate hydraulic fitting

If the place of installation is to bechanged, the clamping and the injectionunit has to be moved to the transportposition as described in "Changing theplace of installation"

6 Press "Hydraulics stop" key

7 Turn off the main switch and use apadlock to prevent accidentalreconnection

Cleaning materials are hazardous to healthand flammable. The manufacturer’sinstructions are to be followed without fail!

8 Dismantle nozzle (and nozzle head), aswell as screw and screw barrel, andclean them

9 Empty hydraulic system

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

Burning hazard if touched. At oiltemperatures above 50 °C (122 °F) wearappropriate Protective clothing! Avoid anyskin contact! If hydraulic oil gets into theeyes, rinse thoroughly with water andconsult a physician!

9.1 Thoroughly clean area around ventingfilter

9.2 Throughly clean the area around thefiller screws and the screw plugs on thetransport and strorage containers for thehydraulic oil

9.3 Unscrew the venting filter lock andremove complete venting filter from fillerstub

Fire hazard! No smoking! Make sure thatthere are no flammable liquids, open flames,etc. nearby!

Environmental hazard! In case of leakinghydraulic oil follow the legal provisions andregulations without fail!

Operation



0

9.4 Empty hydraulic tank with a pump unitvia the filler stub. The suction pipe mustreach to the bottom of the tank

The pump unit must be permissible forhydraulic units

When storing and disposing of hydraulic oilsor used oil, the local laws and regulationsare to be followed without fail. The proprietorof the machine is responsible for properwaste disposal.

The tank must be approved inaccordance with the applicable laws andregulations and must be dimensioned tobe able to hold the hydraulic oil volume(see "Technical Data" chapter)

• Replace the venting filter on the fittingstub

When storing and disposing of hydraulic oilsor used oil the local laws and regulations areto be followed without fail! The proprietor ofthe machine is responsible for proper wastedisposal.

• Drain the remaining oil to a suitablecontainer after removing the shut-offplug or opening the shut-off valves(option)

When disposing of the oil pan and clothsdrenched with hydraulic oil the laws andregulations applicable must be followedwithout fail. The proprietor of the machine isresponsible for proper waste disposal.

When storing and disposing of hydraulic oilsor used oil the local laws and regulations areto be followed without fail. The proprietor ofthe machine is responsible for proper wastedisposal.

• Remove the housing of the pressurefilter. Dispose of the liquid in a suitablecontainer, see chapter "Maintenance",under paragraph "Pressure filter"




Operation0

Emptying the cooling water supply


Burning hazard if touched! Wear suitableprotective clothing with water temperaturesabove 50 °C (122 °F)!

• Cut off the water supply to the oil cooler

• Cut off the water supply to the coolingwater flow control

• Turn the two hand-wheels of the coolingwater flow control clockwise (Closecooling water flow)

• Disconnect the cooling water supply andreturn lines from the oil cooler

• Drain the cooling water from the supplyand return lines of the oil cooler toappropriate systems or containers

• Disconnect the cooling water return (4)from the cooling water flow control anddrain the cooling water to appropriatesystems or container

• Disconnect the cooling water flow (1)from the cooling water flow control anddrain the cooling water to appropriatesystems or container

• Turn both hand-wheels (2+3) of thecooling water flow control cw (Opencooling water flow) and drain the coolingwater to appropriate systems orcontainers

• Disconnect the cooling water flow andreturn (5+6) of the users and drain thecooling water to appropriate systems orcontainers

• Connect the compressed air hose to thefeed lines of the oil cooler and thecooling water flow control and blow outwith compressed air

• Drain the remaining cooling water fromthe supply and return lines toappropriate systems or containers

• Insert plug into the fittings of the supplyand return lines to protect them againstcontamination

Operation



0

Evacuating the compressed air system

If the compressed air system is not relievedfrom all pressure before work starts, there isa risk of explosive emptying with possibledamage or injury!

• Cut off the compressed air supply to theair supply unit

• Turn the pressure adjusting valve (1)counterclockwise until the pressureshown on the gauge (2) sinks to 0 bar

• Turn condensate drain screw (3)counterclockwise; drain condensate to asuitable container; turn condensate drainscrew clockwise

Other measures

• Follow the procedures in the respectiveoperating manuals without fail beforeshutting down the peripheral equipment

• All bare and unplated moving parts andguides (tiebars, piston rods, etc.), and allunpainted, unplated screws must bepreserved using an oily rust preventingagent

1

2

3




Operation0

Disconnecting the electric system

The IMM may only be disconnected from thepower supply by a skilled electrician(according to DIN VDE 0105 or IEC 364). Thesafety regulations in the "Safety" chapter areto be followed without fail!

• Switch off the supply voltage (lowvoltage distribution) to the IMM

• Disconnect the supply lines in thecontrol cabinet from the mains and theheating power terminals

• Secure the cables against interferenceaccording to locally applicableregulations

• Place desiccant medium for protection ofconnections, relays, etc. from corrosioninto the control cabinet

Measures after an extended shutdown

• Clean IMM from dust and rustpreventing agent, see chapter"Transport - Installation"

• Note the service life of the hydraulichoses and hose assemblies, seechapter "Maintenance"

• To prevent the hydraulic pumps frombeing damaged check whether they arefilled with hydraulic oil; see chapter"Transport - Installation."

• Replace the "Back flow filter" and"Venting filter" filter elements; seechapter "Maintenance"

The isolation value may only be checked andwet windings may only be dried by aqualified electrician (according to DIN VDE0105 or IEC 364). The safety regulations inthe "Safety" chapter are to be followedwithout fail!

• Check the insulation values of thehydraulic motor’s windings

• Observe the service life of the battery inthe control unit; see chapter"Maintenance"

Operation



0

• Prepare IMM according to chapter"Transport - Installation"

• Proceed in the same order as describedin "Test run without material" to "Test runwith material"

• Maintain hydraulic system

After extended shutdown, in particular, ifthere are extreme climatic conditions,the movement of some hydrauliccomponents (e.g. valves) may berestricted due to gumming orprecipitations within the hydraulic oil. Forthis reason the IMM should be carefullyrestarted at low set values for themovement speeds and pressures.Carefully observe whether all hydraulicfunctions have been carried out and theproper function of the IMM is ensured

If necessary fill and rinse the IMM with acleaning oil (HLPD according to DIN51524 Part 2, Class ISO VG 32) Theseare hyraulic oils with cleaning additives(identifying letter "D" = "detergents")

After cleaning the IMM is to be refilledand operated with standard hydraulic oil(HLP 46)

• Follow the procedures in the respectiveoperating manuals without fail beforerestarting the peripheral equipment

6.10 Changing the place ofinstallation

• Prepare the IMM as described in "Shutdown procedure"

• Move the injection unit to its foremostposition (into the nozzle platen) beforechanging the place of installation

- Switch off main switch and secureagainst accidental reconnection

• If the IMM is to be moved to an externalinstallation site, lift the IMM using theappropriate lifting equipment, seechapter "Transport - Installation" anddismantle the levelling elements

• Attach lifting equipment as described in"Transporting the IMM" in chapter"Transport - Installation"

• Transport the IMM using the appropriatemeans of tranportation (fork lifting truck,crane) as described in chapter"Transport - Installation"

• If the IMM is to be moved to an externalinstallation site secure the IMM withropes suitable for the weight of the IMMon the means of transportation (e.g.truck)

The complete IMM may only be placedon a level surface capable of supportingthe appropriate load

• Unload, install,level and commission theIMM at the new installation site asdescribed in chapter "Transport -Installation" and start up




Operation0

6.11 Disposal

The proprietors of the machine is obliged todispose of all components, lubricants, hydraulicand gear oil as well as other aids (cleaningcloths, cleaning agents, etc.) according nationaland international laws and regulations.

This applies especially to those componentswhich have been in contact with productshazardous to the environment (lubricants,hydraulic and gear oils).

Please contact the responsible authoritiesbefore disposal. You will receive detailedinformation on laws and regulations applicable,the facilities for disposal, as well as onauthorised waste disposal companies.

Request safety specification sheets according toDIN 52900 for your products from your lubricantsupplier. Among others, these containinformation on waste disposal.

If possible, the materials and substances shouldbe recycled.

The provisions on waste disposal within theEuropean Union (EU) can be found in the"Europäischen Abfallkatlogverordnung" (EAKV)("European Waste Disposal CatalogueRegulation"). This regulation is to translate theprovisions of the decision 94/3/EC on a wastedisposal directory according to Article 1,Chapter a of the Directive of the Council 75/442/EEC on wastes into the German legislation.

In the Directive of the Council 75/442/EECmeasures on the avoidance, recycling and thedisposal of wastes are described in Article 3;Article 4 contains the compliance with theprinciple of non-hazardous waste recycling anddisposal. Article 5 stipulates the principles of thenearest possible and self-reliant waste disposal.

Maintenance

A: PB2GB0MA.P65B: PB2DE0MA.P65E: 180202 / RuderG: 180202 / G. Krajnik

Chapter - 7Page - 1

7.0 Maintenance


Careful installation and care are necessary forthe reliable functioning of the injection mouldingmachine (hereinafter IMM).

Daily visual checks help to prevent down times.Checks, maintenance work and the exchange ofworn out parts should be undertaken at regularintervals. Only parts of the same quality(strength, material) and design may be used.

Breakdowns caused by inadequate or impropermaintenance can result in very high repair costsand long periods of down time. Regularmaintenance is therefore essential.

If you have questions about maintenance orservicing, please contact our Technical ServiceDepartment or one of our subsidiaries. Theaddresses can be found in the "Customerservice" chapter.

The safety regulations in the "Safety"section must be followed without fail!

Before starting any maintenance or repairwork the IMM must be switched off using themain switch and secured against accidentalreconnection.

7.2 Transport, storage anddisposal of lubricants

Lubricants and hydraulic oils areenvironmentally damaging products. For thisreason the local environmental laws andregulations concerning water, building, waste,transport, trade and safety at work must beobserved.

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

Even the strict observance of all laws andregulations can not totally exclude accidentsinvolving lubricants. In such cases theappropriate authorities (Water Board, Police,Fire Brigade) must be notified immediately. Theamount of lubricant discharged beforenotification is required varies from place toplace.

There is therefore a need to make contingencyplans for preventive measures in the case ofany incident with oil. This includes the existenceof such a plan itself, that sufficient oil absorbingmedium is in stock, that drains can be closed offand that tools and materials are available toprevent the spilled oil from escaping.

A: PB2GB0MA.P65B: PB2DE0MA.P65E: 180202 / Ruder


Chapter - 7Page - 2

Maintenance

Request safety specification sheets according toDIN 52900 for your products from your lubricantsupplier.

These cover: (among others)

• Chemical and physical properties.

• Protective measures, storage andhandling

• Measures to be taken in the event ofaccidents and fires

7.3 Disposal of electrical andelectronic components

When disposing of electrical and electroniccomponents, the local laws and regulations areto be observed.

Maintenance


Chapter - 7Page - 3

7.4 Hydraulic oil and lubricant table

These products have been recommended to us by the mineral oil companies. Products from othercompanies which can be shown to be of the same quality may also be used.

Only use prefiltered hydraulic oil of cleanliness class 15/12 to ISO 4406!

*) Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO 4406; always prefilter!**) Only for air cooled three-phase motors

Lubrication point Hydraulic equipment*)

Gearbox, axial bearing and oil

lubrication

Central oil lubrication

Central lubri-cation grease

and+E1 grease

Three phase motors or elec-tric motors**)

Pneumatics and electromag-netic coupling

HLP 46 CLP 220 CG 220 K 2 K - 20 K 3 K - 20 HL 10 / CL 10

DIN 51524 T2 DIN 51517 T3 DIN 51517 T3 DIN 51825 DIN 51825 DIN 51524 T 1

Agip OSO 46

Agip Blasia 220

Agip ASP 220 Agip Exidia 220

Agip GR MU 2

Agip ACER 10

Aral Vitam GF 46

Aral Degol BG 220

Aral Deganit B 220

Aral Aralub HL 2

Aral Vitam DE 10

AVIA FLUID RSL 46

AVIA GEAR RSX 220

Slideway oil RSU 220

AVIA AVIALITH 2

AVIA FLUID RL 10-C

BP Energol HLP-HM 46

BP Energol GR-XP 220

BP Maccurat 220 D

Energrease LS 2

BP Energol HLP-HM 10

Castrol Hyspin AWS 46

Castrol Alpha SP 220

Magnaglide D 220

Spheerol AP 2 SLX Grease Castrol Hyspin

AWS 10

NUTO H 46SPARTAN

EP 220FEBIS K 220 BEACON 2 SPINESSO 10

HYDRAN TS 46

GIRAN 220

HYDRAN G 220

MARSON LA 2 Pluton EM CIRKAN 10

Mobil DTE 25

Mobilgear 630

Mobil Vactra Oil No. 4

Mobil Mobilux 2

Mobil Velocite Oil No. 6

HYDO 46OPTIGEAR BM 220 ULTRA 220 on request

LONGTIME PD 2 FIRETEMP XT2 Hydo 10

RENOLIN B 15 VG 46

RENOLIN CLP 220/220 PLUS

RENEP CGLP 220

RENOLIT FWA 160/GP 2

Q8 Haydn 10

Q8Haydn 46

Q8 Goya 220 Q8 Wagner 220 Q8 Rembrandt

2 Q8 Haydn 10

Shell Tellus 46 Shell Omala 220

Shell Tonna S 330

Shell Alvania R 2

AeroShell Grease 16 Shell Morlina 10

TRIBOL 943 AW-46

TRIBOL 1100/220

TRIBOL 1060/220

TRIBOL 3030/100 Auf Anfrage on request

Designation to DIN 51502



Chapter - 7Page - 4

Maintenance

7.5 Maintenance chart

Every 8 operating hours

• Install all safety devices or all safety guards

• Oil level in hydraulic tank

• Overall condition of IMM (visual check)

• Replace defective indicator lamps immediately

• Always keep the electrical cabinet closed

• Make sure the electrical cabinet is clean


• Check the filter mat(s) in the electrical cabinet fans (option) for clogging

• Check hydraulic fittings, hose asemblies, cylinders, valves, pump(s) etc. for leakages


• Spray all bare parts (tiebars, piston rods, guide rails, linear bearings injection units), wherethere is no movement with a corrosion inhibitor

• Lubricate grease points on moving platen supports and injection side guide (linear bearings)

• Check for scotch bar for proper function.(option)

• Clean filter element of air supply unit (option)


• Operating manual present and correct

• Check the rollers of the limit switches for the clamping units safety gate for cleanliness andfree movement; check whether the limit switches will be sufficiently activated

• Check heater bands for security and correct position

• Tighten all terminals in the switch cabinet

• Check cables (for damage, scorching)

• Change the filter mats of the electriacl cabinet

• Clean electrical cabinet

• Test emergency stop circuit

• Replace hydraulic tank venting filter

Maintenance


Chapter - 7Page - 5


• Clean electric motor fan with dry compressed air; the cleaning intervals depend on the locallevels of airborne dirt

• Check pump motor terminal box for sealing, damaged insulation and secure connections

• Check the stroke transducers on the moving platen and ejector for cleanliness and ease ofmovement

• Check the stroke transducer of the nozzle and the injection cylinder for cleanliness and freemovement

• Visual check of electrical components

• Check nozzle for wear and concentricity

• Test hydraulic oil (replace if necessary)

• Replace back flow filter element

• check all fittings for security and tighten as necessary


• Change hydraulic hose assemblies

• Flush oil cooler and cooling water sight-glasses with a descaler

• Lubricate electric motor bearings



Chapter - 7Page - 6

Maintenance

7.6 Hydraulic unit

Work on hydraulic equipment may only becarried out by a hydraulics expert!


Switch off main switch to secure againstaccidental reconnection. If the clamping platen,injection unit and screw are not in one of theirlimit positions then the hydraulic system isrelieved from pressure. Any residual pressurecan be released by carefully loosening (but notcompletely undoing) a hydraulic fitting.

Oil change

Burning hazard if touched. At oiltemperatures above 60 °C (140 °F) wearappropriate PPE!

When disposing of used oil, legalrequirements must be met. The proprietor ofthe machine is responsible for properdisposal!

Every 5000 operating hours an oil sampleshould be taken and, depending on theanalysis, an oil change be carried out. This is,however, based on an assumed maximumoperating temperature of 60 °C (140 °F) andregular oil filter changes. To establish the oilchange interval suitable for the local operatingconditions it is recommended to test the oil atfirst after shorter intervals (e.g. monthly).

The test sample can be taken from the pressureor return line at operating temperature (e.g. fromthe mini test point (M) on the pump block).

Regardless of the usage the hydraulic oil shouldbe changed after one year at the latest. If the oilis not changed or is changed too late the IMMwill be unreliable and damaged, especially as aresult of abrasive contaminants in the hydraulicoil which can not be removed by the filter.

CautionLeaked oil is always contaminated and mustnever be put back into the hydraulic tank!

Ensure greatest cleanliness! The filler on thehydraulic tank and the spouts and bungs onhydraulic oil drums and storage tanks must bethoroughly cleaned before use. The newhydraulic oil must be checked for ingress ofwater. Oil containing water is spoiled and mustnot be used.

Maintenance


Chapter - 7Page - 7

The oil change should be carried outimmediately after the end of a production run onthe IMM. This ensures that the oil is at operatingtemperature (45 °C to 50 °C / 113 °F to 122 °F)and free flowing with the contaminants still insuspension so that they can be pumped out withthe oil.

Tank capacity 1251 (33 gal)

• Clean the filler screws and the screwplugs on transport and storagecontainers

• Check the hydraulic oil grade; see "Oilquality"

• Prefilter the hydraulic oil through amobile filtration unit

• Switch off hydraulics ("Hydraulics Stop"key)

• Switch off main switch and secureagainst accidental reconnection

• Clean the area round the air ventingfilter

• Undo cap of air venting filter

• Empty hydraulic tank with a pump unitvia the filler stub. The suction pipe mustreach to the bottom of the tank

CautionIf the tank is filled above the max. level,hydraulic oil will come out of the ventingfilter!

The new hydraulic oil may only be filled throughthe air venting filters. This must be done througha separate filtration unit (filter mesh size 3 µm /118.11 µinch), which guarantees a cleanlinessclass of 15/12 to ISO 4406 (Class 6 to NAS1638 or CETOP RP 70H) Experience hasshown that even new oil is not this clean.

CautionOnly use new hydraulic oil and never mixoils of different grades or from differentmanufacturers. The type of oil should not bechanged without compelling reasons. If thisis the case, the system must be flushed outwith the new oil first!

To avoid mixing oils it is recommended to markthe oil tank and fillers with the oil type.

• Fill the hydraulic tank to the maximummark with a mobile filtration unit

The maximum level is shown by theupper marking on the oil level indicator

• Install venting filter again

• Reconnect the bypass filter unit, if fitted

CautionBefore switching on the IMM the hydraulicoil should be allowed to "stand" for approx.1 hour to let the air trapped during fillingescape!



Chapter - 7Page - 8

Maintenance

Air bleeding

After filling the oil tank air must be bled from thehydraulic system.

• Press the "Hydraulic start" key to switchon the hydraulics

• Press the "Setting" key

• Drive the moving platen, injection unitand injection piston to and fro over theirwhole strokeseveral times

The IMM is effectively bled when no foamappears in the oil tank, movements are smoothand there are no strange noises.

The oil level should be checked after bleedingand topped up if necessary. Care must be takento use the same oil type.

Check oil level daily

Continuous monitoring of the oil level is requiredas a drop in the oil level below the markedminimum volume may lead to an increase inoperating temperature, undissolved air andpump failure from cavitation.

Back flow filter

The back flow filter has a contaminationindicator which sends an error message to thescreen if it is triggered.

At the first possible pause in production (e.g.shift change) the filter element (article numberMB628) must be replaced. If there are no sparefilters available one must be orderedimmediately.

The filter must always be changed with the oil. Ifthe above error message or the oil analysisindicates an early oil change, then the oil filtershould be changed early too.

The greatest cleanliness must be maintained.The contamination indicator is suppressed atlow temperatures; i.e. if the oil temperature isbelow 27 °C (80.6 °F) the switch does notfunction.

Maintenance


Chapter - 7Page - 9

Changing the filter element

• Switch off IMM and wait for completepressure loss


Burning hazard if touched. At oiltemperatures above 60 °C (140 °F) wearappropriate PPE!

• Remove element (2); inspect the meshsurfaces for contamination and largeparticles. These can be an indication ofdamaged hydraulic components

• Dispose of filter element (1)

• Before fitting the filter element checkthat the type designation is the same asthat of the filter element removed

CautionDo not attempt to clean or reuse filterelement!

• Renew filter element. The filter can notbe cleaned. Any attempt to clean thefilter will damage the filter material whichwill then allow contaminated oil to reachthe "clean" side of the filter element

• Clean filter cover (4) (inside) with asuitable medium (e.g. white spirit orparaffin), taking care not to introduceany contamination into the clean side

• Inspect the filter unit for mechanicaldamage, especially to sealing faces andseals. Renew damaged parts. Check O-rings and change if damaged

• Unscrew filter cap (3)

• Remove the filter element (1) with thefilter cover (4) on the bracket

3

2

1

4




Maintenance

CautionIf damaged parts are not renewed and if thefilter is not maintained in first classcondition there will be a risk of damaging orreducing the performance of othercomponents in the system!

Venting filter

Venting filters allow the clean air to pass in andout of the oil tank to compensate for changes inoil level. Its effectiveness depends upon theenvironment, but it should be checked and ifnecessary the element renewed after 2500hours at the latest, paying the greatest attentionto cleanliness.

Leaks

Observe any leaks in the hydraulic equipmentand remedy them by resealing or tighteningfittings.

Damaged hydraulic hoses and hoseassemblies must be renewed at once, pleaserefer to the "Hose assemblies" section!

Regular checks of the hydraulic fittings, hoseasemblies, cylinders, valves, pump(s) etc. mustbe carried out every 160 operating hours.

Oil cooler

Although the oil cooler may be consideredmaintenance free, it is recommended to give itsome preventive maintenance every 20,000running hours.

Contaminated water must be filtered and if scaleis present the cooling lines must be descaled.

See also "Water quality".

Hose assemblies

The safety regulations are laid down in DIN20066 Parts 4 and 5 as well as in EN 201. Theycontain regulations on the testing, replacementand storage of hydraulic hose assemblies.

The proprietor of the machine has a duty toensure that hose assemblies are replaced at theappropriate intervals, even if no technicalshortcoming is apparent in the hose assembly.

Service life

Even when stored and used properly are hoseassemblies subject to a natural aging process.For this reason, their use is limited.

Improper storage, overloading and mechanicaldamage are the most common causes of failure.

The service life (including storage time) of hoseassemblies may not be exceeded. Theproduction date is permanently marked on eachhose.

Maintenance



The hose assemblies must be replaced after20000 operating hours at the most.

Reuse

Hoses which have already been in service aspart of a hose assembly may not be reused asthey no longer conform to the requirements ofDIN 20066.

If a hose is reused, then the liability lies with theperson who fits the hose assembly.

Only hose assemblies with sealing heads canbe reused. The length of a hose assembly hasto be determined according to the followingfigure.

Inspection criteria

The proper function is to be checked every 1000operating hours by a skilled hydraulictechnician.

Hose assemblies are to be replacedimmediately if on examination any of thefollowing conditions are found:

• Damage in the outer layer through to thebraiding (e.g. abrasion, cuts or tears)

• Brittleness of the outer layer (cracking ofthe hose material)

• Deformation not consistent with thenatural form of the hose assembly, ineither the pressurised or the relaxedcondition, or in flexure, e.g. delaminationor blistering (see also DIN 20066 Part 4)

• Permeability or porosity

• Damage to or deformation of the endfittings which compromises oil-tightness;light superficial damage is not groundsfor replacement

• Hose creeping out of the end fitting

• Corrosion which reduces function orsecurity of the end fitting

• Installation guideline not observed (DIN20066 Part 4)

• Storage times and service life exceeded

Length includingstandpipe ends




Maintenance

7.7 Water system

CautionWhen using water piping note the corrosionstability of metallic materials against waterin accordance with DIN 50930!

Water piping and the respective fittings are to bechecked for corrosion and leakages by a skilledtechnician at regular intervals.


Burning hazard if touched. At watertemperatures above 50 °C (122 °F) wearappropriate protective clothing!

Water quality

If there are deviations from the followingguidelines please contact our technicalcustomer service or one of our subsidiaries. Theaddresses can be found in the "Customerservice" chapter.

pH value: 6,5 - 9

Water hardness: < 1,8 mmol / l (681 ppm / gal)

Solids: < 0,03 ‰ (30 ppm)

Filter mesh: < 100 µm (0.004 inch)

In the relation of solids content to waterhardness it should be noted that the harder thecooling water is, the lower the solids contenthas to be. If the solids content is above 0.003 %(30 ppm), a water filter with a mesh sizeof< 100 µm (0.004 inch) must be installed in thesupply line.

It is also recommended to add a corrosioninhibitor to the cooling water (e.g. Ferrophos8579 from Henkel).

We recommend ethylene glycol type 420 as anantifreeze (60 % water and 40 % ethyleneglycol). This is suitable for a temperature rangedown to -30 °C (-22 °F) and is also a corrosioninhibitor.

Hydraulic oil temperature

Check the hydraulic oil temperature in the oiltank daily. The IMM is most efficient at an oiltemperature between 45 ° and 50 °C (113 ° and122 °F).

The current hydraulic oil temperature will bedisplayed on the screen (B2 = in the actualvalue field "T12" on page 2 of the "Temperaturecontrol zones" screen page / B4 = "Barreltemperatures 1" screen page).

Maintenance



Oil cooler

• Every 20000 running hours the coolingtubes should be flushed out with adescaling solution to remove anylimescale deposits (max. 16 bar /232 psi)

Cooling water flow controls

• Check cooling water flow controls dailyfor flow and leaks

• Likewise check the cooling waterconnections and hoses for flow (nokinked hoses) and leaks

• The sight glasses may need cleaning ifthe coolant is dirty

• The consumers, moulds, throat cooling,etc. should be flushed out every 20000running hours with a descaling solution


For all work involving fitting, removal,modification and repair, the legal rules andregulations and the safety instructions in the”Safety” chapter must be observed withoutfail!

Work on electrical components may only becarried out by a qualified electrician!

Filter matsThe filter mats can be cleaned as follows:

• Washing in water (up to approx. 40 °C /104 °F, with mild detergent if desired).Shaking, vacuuming or blowing out withcompressed air is also possible

• If the dust is greasy the filter mat mustbe washed out in water with a greasedispersant additive

Buffer battery

The control unit is protected from data loss by abuffer battery. If the error message ”bufferbattery empty” appears the battery must bereplaced. A first battery change must be carriedout after 5 years and consequently every 3years after.




Maintenance

Battery change(Type: Lithium battery 3V/950mA A Nr: BR141)

Data loss without buffering! A copy of theservice and devices data records are savedon disc before the battery change for saftey.

• Switch off main switch

The main switch must be switched backon within 30 seconds of the batterychange, to ensure no data is lost

• Carry out electrical discharge at the tophat rail or at the earth connection (do notreach into the power supply unit)

• Open the battery compartment with thehelp of a screw driver. The screw driveris placed in the groove and thecompartment opened by levering

• Take the battery out of the mount byremoving the cover on the batterycompartment

• Take out lithium battery (do not touchbattery with tongs or non-insulatedtweezers -> shortcut.) The battery mayonly be manually handled on the frontside. To remove the battery insulatedtweezers may also be used

• Insert the battery while observing thecorrect polarity. The removal strip mustbe located underneath the battery,otherwise it cannot be removed

• Close the cover of the lithium battery

• Switch on main switch again

When disposing of the batteries, legalrequirements must be met. The proprietor ofthe machine is responsible for properdisposal!

Maintenance



1234


If the pneumatic system is not relieved of allpressure before work starts, there is a risk ofexplosive emptying with possible damage orinjury!

UNIFEED material feeder

The secondary filter (3) of UNIFEED materialfeeder (option) should be cleaned as necessaryand in any case inspected at least once a week,depending on the amount of dust. Its service lifeis limited and it should be renewed at the firstsign of loose fibres (by simply removing it fromits holder).

The primary filter (2) is automatically cleaned bycompressed air after every conveying cycle. If itbecomes clogged it is cleaned as follows:

• Turn off air supply

• Remove knurled nuts (4)

• Lift off cover (1)

• Clean and replace primary filter (2)

• Replace cover

• Do up knurled nuts (4)

When fitting the filter care must be taken toposition the filter O-ring properly in the grooveprovided.

Filter element (air supply unit).

The interval for cleaning depends on theamount of dirt in the air. An interval of 500operating hours may be taken as a guide.

• Turn off air supply

• Unscrew oil reservoir (9)

• Unscrew filter cartridge

Mechanical scotch

The mechanical scotch (option) will will onlywork if all components are in faultless conditionand moving parts have free movement. Caremust be taken that the face of the scotch (or"flag"), against which a tooth of the scotch-barpresses when it is activated, shows nosignificant wear.




Maintenance

Spares/ Plans

A: PB2GB0NA.P65B: PB2DE0NA.P65E: 180202 / RuderG: 180202 / G. Krajnik

Chapter - 8Page - 1

8.0 Spares/ Plans

The Spares / Plans contains parts lists, plansand drawings which give the circumference forthe IMM, broken down into assemblies. Forevery sub assembly an assembly drawingexists. Each spare part can be found here listedunder a position number.

In order to avoid misunderstandings, it isnecessary to give the Machine Number withevery spare parts order. In addition please statethe Identification number (ID No.), thedescription and the desired quantity.

When ordering, please contact theBATTENFELD agency responsible for you orcontact BATTENFELD direct (addresses andtelephone numbers are given in "CustomerSevice" chapter).

Spares are to be ordered according to theprocedure detailed on the next page.

A: PB2GB0NA.P65B: PB2DE0NA.P65E: 180202 / Ruder


Chapter - 8Page - 2

Spares/ Plans

==

15

15

DOK150000611 8.3.150

15

?

8.3.150

15

Customer Service

A: TB2GB0OC.P65B: TB2DE0OC.P65E: 180202 / RuderG: 180202 / G. Krajnik

Chapter - 9Page - 1

9.0 Customer Service9.1 GeneralThe "Customer service" chapter contains all contactaddresses of all customer service partners andagencies of Battenfeld Injection moulding technology.

A: TB2GB0OC.P65B: TB2DE0OC.P65E: 180202 / Ruder


Chapter - 9Page - 2

Customer Service

Egypt

MEISCAMiddle East Industrial Services & CommercialAgencies27 Ahmed Fakhry Str.,Apt. 2-Zone 6 Nasr CityCairo / Egypt

Tel.: 0020-2-2717032Fax: 0020-2-2717032

Algeria

Wassel Plast SarlCité des Annassers BT. 807 Nr. 8(B.P. 136)Kouba Alger / ALGERIEN

Tel. / Fax: 00213-229-2780Tel. / Fax: 00213-229-2215

Argentina (VAR)

GMO Gabelsberger & Cia.S.A.Av. Belgrano 423/427 Piso 5°1092 Buenos Aires / Argentina

Tel.: 0054-11-4342-7812Fax: 0054-11-4331-7689e-Mail: [email protected]

Australia (VAU)

Battenfeld Australia Pty. Ltd.3, Phoenix CourtBraeside, 3195Melbourne / Australia

Postal address:P.O.Box 614Mordialloc, 3195Melbourne / Australia


Belgium (VBE)

Battenfeld Belgium N.V.Nieuwlandlaan 1AIndustrieparkB-3200 Aarschot Belgium

Tel.: 0032-16-551180Fax: 0032-16-562659e-Mail: [email protected]

Bolivia

Battenfeld do Brasil Ltda. (VBR)(see Brasilia)

Bosnia and Herzegovina

Fokuma Planungs- u. Vertriebsges.m.b.H.Further Straße 27A-2564 Weißenbach

Tel.: 0043-2674-874270043-2674-87413

Fax: 0043-2674-874135e-mail: [email protected]

Brasilia (VBR)

Battenfeld do Brasil Ltda.Rod. Castelo Branco, km 30Av. Gupê, 10.76706422-120 Barueri-SP / Brazil


Bulgaria

WTC GmbH & Co. KGDag-Hammarskjöld-Weg 3D-65760 EschbornDeutschland

Postal address:Postfach 6142D-65735 Eschborn

Tel.: 0049-6196-5010-0Fax: 0049-6196-5010-20

Canada (VCA)

Battenfeld Canada Co. Ltd.940 Westport CrescentMississaugaOntario L5T 1G1 / Canada


Chile

BBL PACK S.A.Av. Pedro de Valdivin No. 3317Nuñoa - Santiage - Chile


China

Agency for: Heilongsiang,Jilin, Liaoning, NeiMongol, Hebei, Sichuan, Shanxi, Shaanxi,Shandong, Gansu, Henang, Beijing, Tianjin

H & ZImport + ExportOffice Beijing Room A 402Long bo BuildingNr. 3, Nanlishi RoadXicheng DistrictP.C. 100037 BeijingP.R. China

Tel.: 0086-10-68025224Fax: 0086-10-68025227

Agency for: Chekiang, Jiangsu, Shanghai,Hupeh, Anhui, Kiangsi, Hunan, Fukien

Royaland InternationalTrading (Shanghai) Ltd.No. 631, Ling Ling RoadAI-LE Building 10HShanghai

Tel.: 0086-21-648668560086-21-648668570086-21-64863796

Fax: 0086-21-64866858e-Mail: [email protected]

Agency for: Guangdong (VHK)

Battenfeld Hong Kong Ltd.2/Fl., No. 18 Dai Fat StreetTai Po Industrial EstateTai Po, N.T.HONG KONG


Columbia

Represantationes maquineqUwe KochCalle 68, No. 12-21, Oficina 304Bogota / Columbia

Tel.: 0057-1-2494581Fax: 0057-1-2494581

Danmark (VDK)

Battenfeld Danmark ASStengaardsvej 74340 Toelloese / Danmark

Tel.: 0045-59185949(TB, KD, Ersatzteile)Fax: 0045-59186922(TB, KD, Ersatzteile)e-Mail: [email protected]

Germany

Battenfeld GmbHScherl 10D-58540 Meinerzhagen / Deutschland

Postal address:Postfach 1164D-58527 Meinerzhagen / Deutschland

Siehe Anhang

England (VUK)

Battenfeld U.K. Ltd.6, The Valley CentreGordon RoadHigh WycombeBucks HP13 6EQ / Great Britain


Ecuador

Battenfeld do Brasil Ltda. (VBR)(siehe unter Brasilien)

Finland (VFI)

OY Suomen Plastmaschinen ABKaakelitehtaankatu 2SF-24260 Salo / Finnland


Customer Service


Chapter - 9Page - 3

France (VFR)

Battenfeld France S.A.Central Parc255, Blvd. Robert BallangerF-93421 Villepinte

Postal address:8, Allée du DaimBoite Postale 42F-93421 Villepinte Cedex


Greece

General Plastics Ltd.Representatives - ImportersLaskaridou 143Kallithea17675 Athens / Greece

Tel.: 0030-1-9567885Fax: 0030-1-9560137

Hong Kong (VHK)

Battenfeld Hong Kong Ltd.Units 910-911No. 1 Hung To RoadKwun TongKowlon


India

Kromes Marketing India13-C Ground Floor,Parmanand Co-op.Hsg. Society,5th Road, Khar West,Mumbai-400052India


Iran

Sunnywell Co. Ltd.3rd Floor, Ark BuildingNr. 316 Ostad Motahari Ave.P.O.Box 15875/5753Tehran / I.R. IRAN

Tel.: 0098-21-88210950098-21-88210960098-21-88331270098-21-8833128

Fax: 0098-21-8821096

Irland

Battenfeld U.K.(see England)

Israel

PLAST-TECH & Co.Industrial & Prod. EngineeringVingait 30 AP.O. Box 492Zihron Ya’acov 30900 / ISRAEL

Tel.: 00972-6-6292333Fax: 00972-6-6292444

Italia (VIT)

Battenfeld Italia S.r.l.Via DonizettiI-20020 Solaro(MI) Italien

Tel.: 0039-2-96 9810450039-2-96 981040

Fax: 0039-2-96 981049e-Mail: [email protected]

Jamaica

Battenfeld Mexico S.A. de C.V. (VMX)(siehe unter Mexico)

Jordan

UCMUnited Chemicals Marketing Est.P.O. Box 1505Amman / Jordan

Tel.: 00962-6-611906Fax: 00962-6-611907

Yugoslavia


Tel.: 0043-2674-874270043-2674-87413


Korea

Trico International Ltd.Room 1007, Dae Ha Bldg.14-11, Yoido-DongYungdungpo-GuCPO Box 892Seoul / Korea


Croatia


Tel.: 0043-2674-874270043-2674-87413


Lebanon

Industrial Engineering Technology S.a.r.l.Sed El BauchriehElectricity StreetP.O.Box 90120 (Jdeidet El Metn)Beirut/Libanon

Tel.: 00961-880597Fax: 00961-880599

Malaysia (VSI)

Battenfeld Injection Moulding Technology (S)Pte. Ltd.Blk. 196, Pandan Loop #01-16Pantech Industrial ComplexSGP 128384 / SINGAPORE


Mazedonia


Tel.: 0043-2674-874270043-2674-87413


Mexico (VMX)

Battenfeld Mexico S.A. de C.V.Antonio Noemi No. 83Col. Lomas de Memetla05330 Mexico, D.F. / Mexico


New Zealand

via Melbourne / Australia

Netherlands

Wilmod B.V.Industrieweg 10NL-2712 LB Zoetermeer / HOLLAND

Postal address:Postfach 40NL-2700 AA ZoetermeerHOLLAND


Norway

Battenfeld Sverige ABc/o Ökonomi Partner Oslo ASPostboks 8704 YonngstargetN-0028 OsloNORWEGEN



Chapter - 9Page - 4

Customer Service

Austria (BKU)

Battenfeld Kunststoffmaschinen Ges.m.b.H.Wiener-Neustädter-Straße 812542 Kottingbrunn / Austria

Tel.: 0043-2252-404-0 (Zentrale)Fax: 0043-2252-404-1062 (Zentrale)

Quality management - Customer serviceTel.: 0043-2252-404-7500Fax: 0043-2252-404-7502e-Mail: [email protected]

Customer service - Hotline MachineryTel.: 0043-2252-404-7511Fax: 0043-2252-404-7505e-Mail: [email protected]

Customer service - Hotline AutomatisationTel.: 0043-2252-404-7590Fax: 0043-2252-404-3902e-Mail: [email protected]

Spare Part SaleTel.: 0043-2252-404-7550Fax: 0043-2252-404-7552e-Mail: [email protected]

TrainingTel.: 0043-2252-404-7410Fax: 0043-2252-404-7505e-Mail: [email protected]

Peru

Battenfeld do Brasil Ltda. (VBR)(see Brasilia)

Poland

Battenfeld PolskaInjection Moulding Technology Sp. z.o.o.Adamowizna 15105-825 Grodisk Maz / Polen

Tel: 0048 22 724 38 07Fax: 0048 90 213 014e-Mail: [email protected]

Portugal (VES)

Battenfeld Iberica S.A.Poligono IndustrialLa FerreriaAvda. La Ferreria 29E-08110 Montcada i ReixachEspagna

Tel.: 0034-93-5646053Fax: 0034-93-5646600

Romania

Jueng EngineeringNiklas-Steuber-Gasse 24A-2361 Laxenburg


Just Plast Technologies srl

Str. Braziliei 14RO-71221 BucurestiTel.: +40 1 2314611Fax: +40 1 2304892Servicehotline: + 40 93 313611e-Mail: [email protected]

Russia

Vadim Zviagintsev1 Novokuznetzkij Per. 5/7-KW 37113184 MoskauRussische Föderation

Tel.: 007-095-9538077Tel.: 007-095-3051466Fax: 007-095-2306261

Sweden (VSV)

Battenfeld Sverige ABRyttarevägen 18A30260 HalmstadSchweden

Postal address:Box 904630009 Halmstad / Schweden


Switzerland (VSZ)

Battenfeld Schweiz AGBrunnenstraße 78604 VolketswilSchweiz


Singapore (VSI)

Battenfeld Injection Moulding Technology (S)Pte. Ltd.Blk. 196, Pandan Loop #01-16Pantech Industrial ComplexSGP 128384SINGAPORE


Slovenia

Fokuma spol. S.r.o.Gololova 1885202 BratislavaSlowakai

Tel.: 00421-7 63811858Fax: 00421-905821858e-Mail: [email protected]

Slovakia

Fokuma spol. s.r.o.Gogolova 18SK-85202 Bratislava / Slowakei

Tel/Fax: 00421-7-638-11-858

Spain (VES)

Battenfeld Iberica S.A.Poligono IndustrialLa FerreriaAvda. La Ferreria 29ES-08110 Montcada i Reixach / Espagna

Tel.: 0034-93-5646053Fax: 0034-93-5646600

South Africa

D.K. Machinery Pty. Ltd.D.K. Machinery HouseNo. 8, Engineering CloseKYA SAND EXT. 15 / South-Africa

Postal address:P.O.Box 21932162 Northriding / SOUTH AFRICA

Tel.: 0027-11-708-2090Fax: 0027-11-708-2085

Taiwan

Royaland Co. Ltd.10-8 Floor, No. 104,Ming-Chuan West RoadTaipei, Taiwan 103 / ROC


Thailand

C. Melchers & Co. (Thailand) Ltd.15th Floor Sorachai Building23/39-39 Sukhumvit 63 Klongton-NuaWatthana Bangkok 10110Thailand

Tel.: 00662-714 30705Fax: 00662-714 3076e-Mail: [email protected]

Customer Service


Chapter - 9Page - 5

Czech Republic

Smid Spol. sro.Ke Kastanku 236CZ-252 18 Uhonice / Tschechische Republik


Turkey

MELTEMMakina Sanayi Ve Ticaret Ltd. Sti.Dogu Sanayi Sitesi Block: 6 Nr. 11Yenibosna 34520 IstanbulTürkei


Tunesia

Battenfeld France S.A.(siehe unter Frankreich)

Hungary

THEGE-PLASTIC GmbHDugonics u. 11H-1043 BudapestUngarn


Uruguay

GMO Gabelsberger & Cia.S.A.(siehe unter Argentinien)

U.S.A. (VUS)

Battenfeld of America, Inc.James P. Murphy Ind. HighwayWest Warwick Industrial ParkWest Warwick, RI 02893U.S.A.


Venezuela

Kast, asesoria tecnica, c.a.Av. Rio Paragua,Res. Prado HumboldtEdf. Cuji, S1, Ofic. CHR-S41081 CaracasVenezuela

Tel.: 0058-2-9765397Fax: 0058-2-9774379

Belorussia

Vadim Zviagintsev1 Novokuznetzkij Per. 5/7-KW 37113184Russische Föderation

Tel.: 007-095-9538077Tel.: 007-095-3051466Fax: 007-095-2306261

Cyprus

M. Sideris & Son. Ltd.18, Pindarus StreetP.O. Box 2353NicosiaZypern

Tel.: 00357-2-75514100357-2-75514200357-2-758300




Chapter - 9Page - 6

Customer Service

Berlin

Bremen

Hamburg

Nürnberg

München

Meinerzhagen

Frankfurt

Dresden

Stuttgart

Kassel

Customer Service Germany

Postfach 116458527 MeinerzhagenScherl 1058540 Meinerzhagen

TrainingTel.: ++49 (0) 2354/72-334Fax: ++49 (0) 2354/72-503e-Mail: [email protected] Spare Parts

Tel.: ++49 (0) 2354/72-161Fax: ++49 (0) 2354/72-139e-Mail: [email protected]

Technical Customer ServiceTel.: ++49 (0) 2354/72-140Fax: ++49 (0) 2354/72-159e-Mail: [email protected]

Spare PartsTel.: ++49 (0) 2354/72-161Fax: ++49 (0) 2354/72-139e-Mail: [email protected]


Spare Parts andTechnical Customer ServiceTel.: ++49 (0) 561/518081Fax: ++49 (0) 561/5102487e-Mail: [email protected]





Head Customer Service: ++49 (0) 2354/72-120Sekretary: ++49 (0) 2354/72-121Telefax: ++49 (0) 2354/72-129e-Mail: [email protected]

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