Maintenance English8580.772.0699M [PDF]

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ENGEL Injection Molding Machine Maintenance Manual 8580.772.0699M

ES25 - 4000

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ENGEL Injection Molding Machine, Maintenance Manual. 8580.772.0699M (Manual, Service) ES25 - 4000 Re-issue 12-12-2005 ENGEL reserves the right to change or update information without prior notification. Due to on going product improvement and various customer options available, ENGEL cannot fully guarantee the accuracy of information contained in this manual. Therefore Engel accepts no responsibility in that respect.

DANGER Complex machine with personal injury hazards. Do not operate machine unless you are properly trained. Read and understand the hazards outlined in chapter 3 of this manual. Before start-up, check safety devices as per chapter 3 - Machine safety checklist. Do not operate machine unless all interlocks/safety devices are in place and function properly. Consult your supervisor, if in doubt about machine safety . Failure to follow instructions could result in injury.

WARNING! ENGEL ADVISES THE USE OF NEW, CLEAN OIL, TO ISO CODE 16/13, IN THEIR INJECTION MOLDING MACHINES. THIS LEVEL OF CLEANLINESS OR BETTER MUST BE MAINTAINED THROUGHOUT THE LIFE OF THE MACHINE. REFER TO ISO 4406 - HYDRAULIC FLUID POWER - FLUIDS - METHOD FOR CODING LEVEL OF CONTAMINATION BY SOLID PARTICLES. USE MINERAL BASED HYDRAULIC OIL WITH A VISCOSITY CLASS OF ISO VG 46 (AT 40O C) RECOMMENDED IN THE TABLE BELOW. CONTACT ENGEL CONCERNING POSSIBLE WARRANTY ISSUES IF ZINC FREE (ASHLESS) HYDRAULIC OIL IS USED IN THE INJECTION MOLDING MACHINE. THE USE OF RECYCLED OIL TO OPERATE AN ENGEL INJECTION MOLDING MACHINE WILL VOID THE WARRANTY OF THAT MACHINE. These documents remain the property of ENGEL (Canada) Inc. And must not be copied without the written consent of ENGEL (Canada) Inc. The contents of this manual may neither be made known to third parties or be used for non-approved purposes.

© 2005 Copyright by ENGEL CANADA INC. Guelph, Ontario,

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© 2005 Copyright by ENGEL CANADA INC. Guelph, Ontario,

MAINTENANCE: 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION - - - - - - - - - - - - - - - 1 1.. MAIN MACHINE ELEMENTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.. THE CLAMPING SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.. DESCRIPTION OF TOGGLE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.. CLAMP CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.. HYDRAULIC EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6.. TIE-BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7.. MOLD HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8.. SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9.. INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 10.. CARRIAGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 11.. PLASTICIZING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 12.. INJECTION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 13.. SCREW DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 14. SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 14.1. PLASTICIZING SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 14.2. TYPES OF SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 15. SCREWTIPS & NON-RETURN VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 16. NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 17. GENERAL MACHINE CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2. GENERAL MACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39 1. LEGEND FOR MACHINE SPECIFICATION TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . 2. MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. TOGGLE INJECTION MOLDING MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. TIEBARLESS INJECTION MOLDING MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . 2.3. VERTICAL CLAMP, HOR. INJ. UNIT, ROTARY TABLE, MOLDING MACHINES. . 2.4. VERTICAL CLAMP, VERT. INJ. UNIT, ROTARY TABLE, MOLDING MACHINES . 2.5. VERTICAL CLAMP, HOR. INJ. UNIT, ROTARY TABLE ELAST MACHINES . . . . . 2.6. HORIZONTAL ELASTOMER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7. DUO PLATEN INJECTION MOLDING MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . 2.8. LARGE TOGGLE INJECTION MOLDING MACHINES . . . . . . . . . . . . . . . . . . . . . . 2.9. PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES

39 40 40 45 48 54 56 57 65 69 76

3. SAFETY DEVICES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 1.. MACHINE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 2.. MECHANICAL SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.1. SAMPLE MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 2.2. ROTARY TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3.. ROTARY TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 3.1. SAMPLE ROTARY MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . 98 3.2. SHUTTLE TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4.. SHUTTLE TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4.1. SAMPLE SHUTTLE MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . 102 5.. SAFETY INSTRUCTION PLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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MAINTENANCE: 4. INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109 1.. MACHINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. INSTALLATION OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. SUNNEX ISOLATION MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. UNISORB ISOLATION MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. ADJUSTMENT OF MACHINE MOUNTS (TOGGLE MACHINE) . . . . . . . . . . . . . . 1.5. ADJUSTMENT OF MACHINE MOUNTS (TIEBARLESS MACHINE) . . . . . . . . . . 1.6. SPLIT BASE MACHINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. SPLIT BASE MACHINES - TIEBARLESS - INSTALLATION - EARLY STYLE . . . . . . 2.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.. SPLIT BASE MACHINE LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . 3.1.1. Levelling the Clamp base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2. Levelling the Injection base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.. SPLIT BASE - TIEBARLESS - INSTALLATION - LATER STYLE . . . . . . . . . . . . . . . . 4.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.. SPLIT BASE MACHINE LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . 5.1.1. Levelling the Clamp base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2. Levelling the Injection base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.. VERTICAL CLAMP - MACHINE LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.. INSTALLING AND SET-UP OF MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. SECURING THE MOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. INSTALLING MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.. SETTING CLAMP FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.. SETTING MOLD PROTECTION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.. MOLD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.. MOLD OPEN - STROKE LIMITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.. REMOVAL AND REPLACEMENT OF INJECTION SCREW. . . . . . . . . . . . . . . . . . . 13.. BARREL REMOVAL AND REPLACEMENT INJECTION UNITS 80-330). . . . . . . . . 13.1. CENTERING THE 80 - 330 INJECTION UNIT - OLDER STYLE. . . . . . . . . . . . . 13.2. CENTERING THE 80 - 330 INJECTION UNIT - NEWER STYLE . . . . . . . . . . . . 13.2.1. MEASUREMENT OF NOZZLE CENTERING . . . . . . . . . . . . . . . . . . . . . . . 13.2.2. SWIVELLING THE INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3. CENTERING NOZZLE - 650 & UP - PREVIOUS STYLE INJECTION UNIT . . . . 14.. CENTERING THE INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1. CENTERING & LEVELLING INJECTION UNITS - 650 & UP - LATEST STYLE 14.1.1. MEASUREMENT OF NOZZLE CENTERING . . . . . . . . . . . . . . . . . . . . . . . 14.1.2. CENTERING THE NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2. SWIVELLING THE INJECTION UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.. SWIVELLING THE INJECTION UNIT - IN-LINE INJECTION UNITS. . . . . . . . . . . . . 16.. ADJUSTING NOZZLE HEIGHT - VERTICAL ROTARY BRIDGE MACHINES . . . . . 16.1. TO RAISE AND LOWER THE HORIZONTAL INJECTION UNIT. . . . . . . . . . . . . 17.. SCREW TIP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.. TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1. CAP SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2. MOLD MOUNTING BOLTS - U.N.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.. ANTI-SEIZE COMPOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.. INSTALLATION OF HEATER BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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109 110 111 112 113 114 115 118 118 121 121 121 123 125 125 127 127 127 129 130 132 132 133 134 135 135 136 138 142 144 145 145 146 147 148 148 149 149 151 152 154 154 156 158 158 160 161 162

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MAINTENANCE: 5. START UP AND SHUT DOWN PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - 163 1.. STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. MACHINE SHUT-DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.. MANUAL TO AUTOMATIC CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.. CORES AND EJECTORS SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163 165 166 166

6. HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 167 1.. BASICS OF HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. CONVERSION OF ENERGY IN HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. DIRECTIONAL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. INJECTION MOLDING MACHINE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 3.. HYDRAULIC SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.. HYDRAULIC OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1. HYDRAULIC FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. HYDRAULIC FLUID VISCOSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3. FILTRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1. HIGH AND MEDIUM-PRESSURE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2. HYDRAULIC SUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. HYDRAULIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. HYDRAULIC PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1. Variable Displacement Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. CHECK VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1. Pilot Operated Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3. PRESSURE RELIEF VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1. Pilot Operated Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2. Directly Controlled Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3. Pilot Operated Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. DIRECTIONAL CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1. Pilot Operated Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. PROPORTIONAL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1. Proportional Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2. Proportional Flow Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3. Proportional Solenoid with Position Transducer. . . . . . . . . . . . . . . . . . . . . . . 5.5.4. Proportional Directional Control Valves (Pilot Operated) . . . . . . . . . . . . . . . 5.6. OPEN LOOP VERSUS CLOSED LOOP (MOOG VALVE) . . . . . . . . . . . . . . . . . . 5.6.1. Moog Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2. Two Stage Moog Valve With Closed Loop Position Control . . . . . . . . . . . . . 5.6.3. Three-Stage Moog Valve With Closed Loop Position Control . . . . . . . . . . . . 5.7. CARTRIDGE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8. CARTRIDGE VALVES EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9. PRESSURE GAUGE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10. HYDRAULIC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11. HYDRAULIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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167 168 179 184 185 200 201 204 209 211 213 221 224 224 230 231 235 236 237 238 239 243 244 245 246 247 248 249 250 251 252 253 259 262 263 265

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MAINTENANCE: 7. ELECTRICAL SYSTEM. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 271 1.. ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. HOW TO READ THE ENGEL ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . 1.1.1. physical location naming convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2. Electrical Line Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3. Page and Line numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.4. Typical examples explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. THREE PHASE INDUCTION MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.. MOLD HEIGHT MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.. TRANSFORMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.. CARD RACK POWER SUPPLY UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.. RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.. SOLID STATE RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.. VARISTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.. SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.. DC SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.. FANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.. RECEPTACLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1. 460 VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2. 230 VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3. 120 VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. TRANSDUCERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1. STROKE TRANSDUCERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2. CLAMP FORCE STROKE TRANSDUCER (LVDT) . . . . . . . . . . . . . . . . . . . . . . . 13.3. HYDRAULIC AND MOLD CAVITY PRESSURE TRANSDUCERS . . . . . . . . . . . 13.4. SCREW RPM TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5. THERMOCOUPLE TRANSDUCERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.. STANDARD SOLENOID LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.. SETTING MINIMUM AND MAXIMUM BALANCE ON PA88 CARD . . . . . . . . . . . . . 16.. SETTING THE MINIMUM / MAXIMUM POINT FOR PRESSURE (K-VALVE) - A02 CONTROLS (30 TON - 500 TON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. SETTING THE MINIMUM /MAXIMUM POINT FOR SPEED (Y-VALVE) - A02 CONTROLS (30 TON - 500 TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . 19. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER -TYPE LG93 . . . . . . . . . . 20.. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - TYPE LG99 . . . . . . . . . 21.. USING THE MICROGRAPH AS AN OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . . . . 22.. TROUBLESHOOTING PROPORTIONAL VALVE CIRCUIT . . . . . . . . . . . . . . . . . . . 22.1. HOW TO SET UP PRESSURE VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2. TESTING CLAMP PROPORTIONAL VALVE FUNCTION. . . . . . . . . . . . . . . . . .

272 274 274 275 275 275 280 285 286 289 290 290 292 293 294 295 295 295 295 295 297 298 299 300 302 302 317 325 327 329 331 332 333 335 337 339 342

8. PNEUMATIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 347 1.. AIR SERVICE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 2.. LUBRICATOR UNIT (OIL MIST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

9. COOLING SYSTEM. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 349 1.. HEAT EXCHANGER (OIL COOLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

d

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MAINTENANCE: 10. LUBRICATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 353 1.. OIL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. GREASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. HYDRAULIC OIL AND LUBRICANT COMPARISON . . . . . . . . . . . . . . . . . . . . . . 2.2. TRABON AND VOGEL AUTOMATIC GREASE LUBRICATION . . . . . . . . . . . . . .

353 356 363 363

11. PREVENTIVE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 367 1.. GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. SUGGESTED LOCKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.. CONTROLS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.. MACHINE CHECKS AND INSPECTIONS (SEMI - ANNUAL) . . . . . . . . . . . . . . . . . . . 6.. CHECKING AND ADJUSTING MACHINE LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1. ADJUSTMENT OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. EUROMAP 7 TEST BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.. CHECKING AND ADJUSTING MOVING PLATEN BEARING SUPPORT . . . . . . . . . 7.1. MOVING PLATEN BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.. CHECKING PLATEN PARALLELISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.. TIEBARLESS MACHINES - PLATEN PARALLELISM . . . . . . . . . . . . . . . . . . . . . . . . 9.1. ROTARY LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2. ADJUSTMENTS FOR MAINTAINING PLATEN PARALLELISM: . . . . . . . . . . . . . 9.3. “FLEX – LINK” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.. TOGGLE MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1. CHECKING PARALLELISM AND TIE BAR STRETCH . . . . . . . . . . . . . . . . . . . 10.1.1. Platen Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.2. ADJUSTING PLATEN PARALLELISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2. TIE BAR STRETCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1. CLAMP FORCE CALCULATION (metric & imperial) . . . . . . . . . . . . . . . . . 10.2.2. CHECKING TIEBAR STRETCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3. Tie Bar Stretch calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.4. ADJUSTING TIEBAR STRETCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.. PLASTICIZING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

367 368 368 369 371 380 380 380 381 381 383 384 384 385 387 389 389 389 390 392 392 393 395 396 400

12. GENERAL TROUBLESHOOTING FLOWCHARTS - - - - - - - - - - - - - - - - - - - - 405 REVISION LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 417

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e

MAINTENANCE:

f

16/12/05

MAINTENANCE: 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION ENGEL injection molding machines employ a hydraulically based system to provide the extremely high clamping pressures required in the production of modern thermoplastic products. The hydraulic pump is driven by an electric motor and the plastic injection process is achieved through a screw drive mechanism.

1.

MAIN MACHINE ELEMENTS:

A. Machine frame with: • Electric motor • Pump • Hydraulic unit B. Clamping unit with : • Platens and Tie-bars • Clamping Cylinder • Toggle System • Safety Gate C. Injection unit with: • Plasticizing Cylinder • Injection Cylinder • Carriage Cylinder • Screw Drive • Material Hopper D. Control cabinet (AC) (on machine) with: • Main Connection • Master Breaker Switch • Motor Breaker Switch • Heating Breaker Switch • * Programmable Controller E. Control cabinet (separate) with: • Electronic control • * Programmable controller (Optional) *The programmable controller might be placed in either cabinet depending on the specific machine.

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

1

MAINTENANCE: The injection molding machine basically consists of two parts; a horizontal press, and an extruder with an injection cylinder. A frame of hollow structural design, supports the horizontal clamping press and the injection unit. The right-hand part of the frame accommodates the oil reservoir and part of the manifold system. The left-hand side provides a large drop off area to accommodate bins or conveying system.

TYPICAL HYDRAULIC MACHINE

TYPICAL TOGGLE MACHINE

2

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

16/12/05

MAINTENANCE:

1

Clamp Cylinder

2

Safety Gate

3

Clamp Piston

4

Tie-bars (times 4)

5

Ejector

6

Moving Platen

7

Stationary Platen

8

Plasticizing Cylinder

9

Material Hopper

10

Injection Unit

11

Screw Drive Motor

12

Monitor and Front Faceplate

13

Alarm Light

14

Part Drop-out Area

15

Carriage Piston

16

Card Rack (inside left door)

17

Master Disconnect Switch

18

Machine Mount (adjustable)

Component Layout - 30/55 Ton Hydraulic Clamp

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

3

MAINTENANCE: 3

4

2

6

11

12

9

15

10

11

13

17

1

14 18

8

16

1

Clamp cylinder

2

Safety gates

3

Clamp piston

4

Prefill Hydraulic oil tank

5

Ejector

6

Moving Platen

7

Stationary Platen

8

Plasticizing Cylinder

9

Material Hopper

10

Injection unit

11

Screw Drive Motor

12

Monitor and front faceplate

13

Alarm light

14

Part drop out area

15

Carriage piston

16

Card rack (inside left door)

17

Master disconnect switch

18

machine mount (adjustable)

Component Layout 100 Ton

4

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

16/12/05

MAINTENANCE:

1

Clamping cylinder

2

Tie bar (x4)

3

Rear platen

4

Toggle area

5

Ejector cylinder

6

Moving platen

7

Safety gate

8

Monitor

9

Plasticizing cylinder

10

Material hopper

11

Injection unit

12

Screw drive motor

13

Master disconnect switch

14

Card rack

15

Manual switches

16

Part drop out area

17

Machine frame

18

Machine mount (adjustable)

19

Mold height motor Component Layout 85/100 Ton

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

5

MAINTENANCE: 2

1

19

4

3

5

6

15

14

9

11

8

16

17

12

10

1.

Clamping cylinder

2.

Toggle mechanism

3.

Tie bars (x 4)

4.

Ejector cylinder

5.

Moving platen

6.

Safety gate

7.

Manual control switches

8.

Purge gate

9.

Plasticizing cylinder

10.

Carriage cylinder (x 2)

11.

Material hopper

12.

Injection unit

13.

Screw drive motor

14.

Monitor and front faceplate

15.

Part drop out area

16.

Card rack

17.

Carriage linear bearing (x 2)

18.

Master disconnect switch

19.

Machine mount (adjustable)

13

18

Component layout 200 Ton (150 - 500 Ton series)

6

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

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MAINTENANCE: 2.

THE CLAMPING SIDE

The clamping side consists of: Clamping Unit - Platens and Tie-bars. On all Engel machines, the stationary platen is mounted to the base. The clamping cylinder platen, which is the left hand platen when standing on the operator-side of the machine, is allowed to float, to a certain extent, in order to permit tie-bar stretch during clamping. The moving platen, guided on four tie-bars, is supported with roller supports on larger machines (on smaller machines the roller supports are optional). The moving platen also contains long guide bushings which ride on the highly polished surface of the tie-bars. The clamping and opening movement of the platens is achieved either by direct hydraulic action (28 ton and 45 ton) or hydraulically activated toggle mechanism. Mold mounting and ejector hose on the platen are according to SPI standards. The stationary platen is equipped with cooling holes to minimize heat transfer from the plasticizing unit or hot runner mold into the clamp system. Clamp System - ES 30 and 55. Both machines are fully hydraulic machines with a high speed closing cylinder and a high pressure cylinder and pre-fill valve. The older type of ES25, ES28 and ES45 are clamped up with the full clamping cylinder rod and have a high speed opening cylinder.

3.

DESCRIPTION OF TOGGLE SYSTEM The clamp force is generated by the means of a double folding toggle mechanism. The toggle system consists of the following parts: • Crosshead • Left-hand connecting fork • Right-hand connecting fork • Link Right • Link Left • Latches • Toggle Pins The toggle pins are case hardened and the bushings are made from hardened tool steel. Each bushing of the toggle mechanism is individually lubricated by the oil lubrication system.

4.

CLAMP CYLINDER The hydraulically activated cylinder for the clamp system is mounted to the cylinder platen. The hydraulic cylinder provides the necessary force for opening and clamping the machine, and it is also equipped with a hydraulic cushion for maximum opening stroke.

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

7

MAINTENANCE: 5.

HYDRAULIC EJECTOR The hydraulic ejector plate is mounted to the back of the moving platen by means of guide rods. The ejector provides enough adjustable force to eject the parts. Newer machines are provided with an arrangement to connect the ejector rod to the mold platen for easier return of the ejector plate.

6.

TIE-BARS The tie-bars are made from a high quality pre-hardened steel alloy which has been induction hardened and super-finished for wear resistance. The threaded sections however are unaffected by the induction hardening process. The tie-bars act as springs during clamp lockup and stretch to allow for proper clamp force (typical tie-bar stretch is 0.030" at nominal clamp force). On machines of 400 tons, or less, the section of tie-bar within the stationary platen is preloaded, according to the tonnage of the machine. On a 300 ton machine, for example, each tie-bar would be preloaded to a minimum of 75 tons. This effectively prevents tie-bar movement within the platen whilst distributing the load into the platen via hardened inserts.

7.

MOLD HEIGHT ADJUSTMENT Mold height adjustment is performed over the long threaded ends of the tie-bars, on each tie-bar nut a gear is mounted and is driven by a central gear, this in turn is driven by the mold-height motor via a reducing gearbox. Operating the key switch, "mold height adjustment" on the push-button station, enables the mold-height to be increased or decreased.

8.

SAFETY GATE The safety gates protect personnel from all pinch points on the clamp unit and also activates all safety devices on the machine such as mechanical drop bar, hydraulic interlock and electrical limit switches. Protective guards are an integral part of the machine and can only be removed with hand tools. Operation of the machine without these safety guards is dangerous to personal safety and forbidden by safe factory working conditions. To allow observation of the mold and clamp mechanism, as well as the hydraulic ejector, the safety gate and guards are equipped with large windows wherever deemed necessary. On split gate designs the rear door can be opened for service accessibility, although if the rear door is opened, the machine will shuts off.

9.

INJECTION UNIT The injection unit consists of: • Carriage Cylinder • Plasticizing Cylinder • Injection Cylinder • Screw Drive Assembly

8

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

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MAINTENANCE: 10.

CARRIAGE UNIT The carriage unit is the complete injection unit riding on two guide rods mounted to the base. Two carriage cylinders are mounted to the injection unit which provide the necessary nozzle force and nozzle travel. The two piston rods are connected to the stationary platen, symmetrical about the machine center line. Nozzle pressure and nozzle speed are independently adjustable from zero to maximum.

11.

PLASTICIZING CYLINDER The plasticizing cylinder consists of: • Cylinder, Screw • Barrel Head • Nozzle Heater Bands • Thermocouple • Screw Tip Assembly. Plasticizing cylinders and screws are available for special molding applications. The standard screw, is nitrided, and used in conjunction with a nitrided plasticizing cylinder, this arrangement is suitable for processing a wide range of thermoplastic material. A large variety of different nozzles designs are available for special applications, such as optional hydraulically activated shut-off nozzles, spring-loaded shut-off nozzles, reverse taper nylon nozzles, extended nozzles and heaterless nozzles.

12.

INJECTION CYLINDER The injection cylinder is a double-acting cylinder providing sufficient force for high injection pressure speed, as well as position suckback for melt decompression. The cylinder is mounted to the cylinder-casting of the injection unit. The hydraulic force is transmitted over the floating screw drive onto the screw generating injection pressure.

13.

SCREW DRIVE ASSEMBLY On our older generation of machines up to 70 ton and on all our newer generation of machines, a direct hydraulic drive is used. It basically consists of a high torque - low RPM hydraulic motor, main drive shaft and shaft bearings. The unit itself is maintenance free. On the older generation of machines starting with the 110 ton, a reduction gear in conjunction with a high speed - low torque hydraulic motor is used. The unit must be maintained directly according to our maintenance recommendations. The main drive shaft contains a female spline which accepts the splined shaft of the plasticizing screw. The initial connection is provided by a split ring and drop nut. When reconnecting the screw to the gear assembly, it is important that the two “C” halves of the split ring sit properly in the front counter bore of the main drive shaft before tightening the locknut to prevent severe damage to screw and drive shaft.

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

9

MAINTENANCE: 14

SCREWS

14.1

PLASTICIZING SCREWS

HEATER BAND

NOZZLE HEATER BAND

THERMOCOUPLE

NOZZLE BARREL SCREWTIP

A3001372

SCREW

The most important part in an injection unit is the plasticizing screw. It is used to melt the material in the plasticizing cylinder. The design considerations and manufacturing quality of a screw is important, in order to achieve the following characteristics: • Very good plasticizing capability. • Good color mixing, by dry color material or master batch. • Constant material feed. • Development of very little friction heat. • Use of many different plastic material types. If all these characteristics were maximized, the result would be the ideal universal screw. However all screw design is a compromise. If the screw design has a very high feed capability, the mix capability will be affected. If the mix capability is raised, there is a possibility of generating too much friction heat and thereby slowing down the feed capability. Therefore, a compromise must be made. Most machine manufacturers, have designed a general purpose screw for manufacturing with frequent material changes. The screw is designed for good feed rate, good mixing ability, low friction heat and good wear quality.

10

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

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MAINTENANCE: 14.2

TYPES OF SCREW. There are a large number of different materials being injection molded. Each material has its own individual characteristics resulting in unique molding problems for that material. This has given rise to many innovations in screw design. Some of the most commonly used screw types will be discussed in this section.

A. Thermoplastic Screws. Thermoplastic Screws or general purpose screws are used for plastic material, polyethylene, polypropylene and polystyrene. The general purpose screws are divided into three zones from the hopper end of the machine: 1. Feed zone - As the material falls from the hopper into the screw, the feed zone warms the material and the deep flights of the screw transport the material to the second zone. 2. Transition zone - The flight depth of the screw is much shallower in this zone and the material is compressed against the wall of the cylinder as it is transported to the last zone and starts to melt. 3. Metering zone - Here the flights of the screw are very shallow and the material is melted into the final liquid stage, mixed and transported to the front of the screw tip. At the screw tip it is ready for injection into the mold. Two important measurements are always given for a screw, L/D ratio and compression ratio. The effective screw length to diameter ratio (L/D) is the distance from the forward end of the screw flight divided by the diameter of the screw. General purpose screws commonly have an L/D ratio of 20:1. Typically, on a screw with 20 flights, this might be divided between the three zones as 40% (8D) in the feed zone, 35% (7D) in the transition zone and 25% (5D) in the metering zone. The compression ratio is obtained by dividing the volume of the screw channel at the feed opening by the volume of the last flight prior to discharge, a ratio of 2 or 3:1 would be common. L

D

METERING ZONE

TRANSITION ZONE

FEED ZONE

TYPICAL THERMOPLASTIC SCREW

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

11

MAINTENANCE: The L/D ratio of a screw for processing polyethylene and polypropylene is quite different because of the greater shear strength of the material. Typically the screw would be divided up as follows: Feed zone

-

60% (12D)

Transition zone

-

20% (4D)

Metering zone

-

20% (4D)

General purpose screws are normally case hardened using a process known as nitriding. A very hard outer case can be obtained by subjecting the screw to a nitrogen rich atmosphere at elevated temperatures. The depth of case is approximately .020 - .024 inches. When any significant wear has taken place and the case hardening has been worn through, the screw will experience rapid wear of the softer inner material. Non filled materials should be used with this type of screw. Materials such as glassfill, micafill and quartzfill require a specially coated screw because of the corrosive acids found in these materials. Thermoset Screws When molding thermoset materials such as phenolic and melamine a screw with the following characteristics is used: L/D ratio

=

16

Compression ratio

=

low 2’s

The screw is mainly used for transporting the material, so little or no compression is required. The nose of the screw is tapered, with the flights extending almost to the tip, instead of an actual screw tip. Screw cooling is used to prevent over heating when the screw has a large diameter (2.75 inches and over).

12

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

16/12/05

MAINTENANCE: Elastomer Screws Elastomer screws used for rubber, are a three compression type with the following characteristics: L/D ratio

=

Compression ratio

=

16

Very little compression is required for rubber and the screw is mainly used for transport of the material. Lim Screws LIM (Liquid Injection Molding) screws provide no compression and are for material transport only.

A3000627

Polyester Screws Polyester screws provide no compression and are for material transport only.

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

13

MAINTENANCE: Vented screws DECOMPRESSION AREA

METERING

VENTING

FEED

2ND

1ST

TRANSITION

TRANSITION

A3001263

METERING

Vented screws are used to mold ABS, polycarbonate and nylon. The screw appears to be two screws joined together. The material is dried in the barrel and the moisture vapour or gases are vented through a hole in the barrel. If the vapour were prevented from escaping then, the vapour would be compressed by the melted plastic and carried to the mold. Once in the mold, the vapour will expand and cause bubbles in the molded part. To allow the vapour to escape before it reaches the mold, the molten plastic is decompressed half way along the barrel. This is achieved by reducing the diameter or root of the screw. At the point of screw diameter reduction, a hole is located in the barrel for vapour to escape through. Special attention has to be given to accurate heating and heating zone transfer from zone to zone. A vented screw should have the screw speed adjusted so that almost all of the screw rotation time is used. This provides a good melt without excessive shear and increases the time that the melt is tumbled in the vent zone to allow the escape of vapour or gases. Back pressure should be kept to a minimum to allow the screw to recover properly and to prevent material from flowing through the vent hole. When using vented screws and barrels a loss of plasticizing capacity of up to 40% can be expected compared with a standard screw of the same diameter.

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MAINTENANCE: 15

SCREWTIPS & NON-RETURN VALVES

Sliding Ring Check Valve. Most Engel injection molding machines are fitted with a free-flowing screw tip. The freeflowing screw tip consists of a stationary seal ring, floating check ring and a deeply grooved tip. During plasticizing the free-flowing check ring is pushed to the front of the tip to allow material to flow underneath the ring to the front of the tip. When the screw stops turning and begins the injection cycle the pressure of the plastic plus the injecting of the ram forces the ring back against the seat to prevent any back flow of the material. It is important that this free floating seal ring has a good seal seat (no scratches) against the stationary seal ring. Back flow of material could result in uneven shots and bridging in the feeding section. If during injection uneven shots occur or a loss of cushion stability, it will be necessary to check the seal ring, stationary ring and tip for wear or cracks.

CHECK RING VALVE SEAT

SCREW TIP Sliding ring check valves are most commonly used for their free flow design that creates very little pressure drop, across the valve, which is ideal for processing heat sensitive materials.

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MAINTENANCE: Cam Actuated Check Valve

CAM

CHECK RING

A3001385

PIN DIRECTION OF ROTATION

TIP

The plasticizing pressure presses the CHECK RING against the PIN. The PIN interlocks with a CAM which is machined into the CHECK RING and rotates with the screw. Depending on the amount of material which is plasticized, the CHECK RING lifts off a corresponding amount from its seat. At the end of plasticizing, the screw slows down according to a fixed speed ramp. As the screw slows down, the plasticizing rate also decreases. Since the plasticizing rate determines the clearance between the CHECK RING and the TIP, the gap decreases proportionally to the decreasing screw speed. At the end of plasticizing, the CHECK RING is already in a closed position. Because of this effect, the CHECK RING does not have to travel as far (or not at all) to reach the closed position when the screw moves forward during the injection cycle - hence more consistent shutoff and closer shot size control. Increased cylinder wear has been noticed when using filled materials because the ring is forced to rotate with the screw (same as with BALL CHECK valves). Therefore this type is not recommended for filled materials.

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MAINTENANCE: Ball Check Valves Ball check valves perform in a similar manner to sliding ring check valves, but have some advantages in that they provide better shot control and a more positive shut off. Ball valves however do have some disadvantages, because their design is not so streamlined as the ring valve they produce a greater pressure drop across the valve and therefore more heat. This makes them unsuitable for handling heat sensitive materials and so they are mainly used for polystyrene, polyethylene and polypropylene. A ball check valve comprises a floating steel ball, held in place by a crosspin that closes the flow of material during injection. The material is either discharged through the front of the valve or the side. The front discharge type is less expensive than the ring type and operates well with less viscous materials, but is harder to clean. The side discharge type has all the characteristics of the front discharge type and is much easier to clean, but is more expensive.

INLETS

FRONT DISCHARGE

FRONT DISCHARGE TYPE BALL CHECKVALVE

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MAINTENANCE: Smeartips When molding materials like PVC, normal screw tips cannot be used, and Smear tips are employed instead.

HIGHLY POLISHED

A3001266

CHAMFERED TIP (little heating)

When using a smear tip, the front nozzle flange and nozzle have to be changed to match each other. The angle of the smear tip, flange and nozzle must be accurately fitted together and the gap between the screw tip, flange and nozzle must not exceed 0.015". Since this type of design does not use a check ring it is necessary that an anti-rotation device, either hydraulic or mechanical, be installed in the machine to prevent back flow of plasticized material.

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MAINTENANCE: Spring Loaded Check Valve This type is used for L.I.M (liquid injection molding)

SPRING

A3000047

DISCHARGE HOLES

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MAINTENANCE: 16

NOZZLES At the front end of the injection cylinder is the nozzle, which is screwed into the cylinder flange and makes the connection between mold and machine.

TYPICAL NOZZLE ARRANGEMENT The nozzle normally has a radius, according to SPI standards of 1/2" (up to 400 ton machines) to 3/4" (over 400 ton machines)." The radius of the nozzle should be slightly less than the sprue bushing radius so that only the nozzle hole or the front most end of the nozzle is connected to the mold. The outer part of the radius should be free and not touching the mold.

R r

SPRUE BUSH NOZZLE R (SPRUE BUSH) = r (NOZZLE) + 0.020 TO 0.040 INCHES

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MAINTENANCE: It is very important that the hole of the nozzle be the same size, or a little less than, the size of the hole of the sprue bushing. A very small hole in the nozzle will result in high injection pressure and more shearing which will heat up the material. Nozzles over 1" in length should be supplied with their own heating zone and their own heater band to permit good control over the temperature of the nozzle. Nozzle Types There are a variety of nozzles available depending upon the material or mold parameters required. Some of the types of nozzles include: • Insulated. • Reverse tapered. • External spring shut off or internal spring shut off. • Hydraulic shut off Insulated nozzles are mainly used for single cavity molding, where the part can be reached in the mold to achieve a hot runner molding effect. Reverse taper nozzles are mainly used to mold nylon, where the front channel of the nozzle is reversed to taper off the back channel. Standard Nozzle Used for general purpose molding where a special nozzle is not required.

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MAINTENANCE: Plunger Nozzle This is an extended rigid nozzle, which is used with hot runner molds.

Thermoset

PVC Nozzle

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MAINTENANCE: Ante-Chamber Nozzle This nozzle plunges into the mold for sprueless injection. Due to the high conductivity of the copper tip of the nozzle the material does not freeze in the antechamber of the sprue bush.

Shutoff Nozzles The controlled shut off type of nozzle is employed to eliminate drooling of the material. They are also preferred when the plasticizing time is longer than the cooling time and if the plasticizing occurs with nozzle retracted for improved mold cooling and less nozzle cooling. The hydraulic shut off nozzles are in fact hydraulic open nozzles, in the event of hydraulic failure the shut off nozzle would close, this is termed "fail safe".

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MAINTENANCE:

BARREL HEAD

PLAST. CYLINDER

FEEDTHROAT

NOZZLE

ACTUATING FORK

HYDRAULIC CYLINDER

ROTARY VALVE

BARREL HEAD

A3000043

PLA. CYLINDER

OPEN NOZZLE

CLOSED

OPEN

CONNECTING ROD

HYDRAULIC CYLINDER A3000044

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MAINTENANCE: Variable

Description

A A1 A2 A3 AH AZ B B1 B8 BG2 C1 C1* C2 C2* C3 C3b C3d C3E C3u C4 CP CPx DZx FA FZx G1 G1A G2 G2f H1x H2x J J1 K K1 KA1 KA2 KA3 KD1E KD2E KD3E KE1 KE2 KE3 KH1A KH1E KH2A

Mold open position Mold position to start ejector Start air blowing 1 Start air blowing 2 Minimum opening stroke robot Ejector counter (number of times ejector comes forward) Toggle lever locked Start toggle lock slowdown (A01) Move in before tonnage (cores) End mold protection pressure (A01) Set screw feed stroke Corrected feed stroke (corrected by the cushion program) Decompress after feed Decompression stop (corrected feed stroke plus decompression) Stroke cut-off point Hydraulic pressure cut-off window Cut-off window (screw position before parallel cut-off) External cut off Screw position at cut-off Decompress before feed Cushion length set value Actual cushion length Actual screw feed speed (rpm) Number of cavities Flow number () Start of mold protection Start of 2nd mold protection (A01) Start clamping pressure (toggle lever position) Stop mold protection (mold position) Temperature - heat zone 1 Temperature - heat zone 2 ....etc. Nozzle contact position Start 2nd nozzle forward speed Sprue break stroke Nozzle fully retracted Monitor position for core out (1) Monitor position for core out (2) Monitor position for core out (3) Valve off after movement (core 1) Valve off after movement (core 2) Valve off after movement (core 3) Monitor position for core in (1) Monitor position for core in (2) Monitor position for core in (3) Using auxiliary power source (core 1 out) Using auxiliary power source (core 1 in) Using auxiliary power source (core 2 out)

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MAINTENANCE: Variable KH2E KH3A KH3E KO1 KO2 KO3 KP1A KP1E KP2A KP2E KP3A KP3E KRZ KS1 KS2 KS3 KT1A KT1E KT2A KT2E KT3A KT3E KV1A KV2A KV3A KZ1A KZ1E KZ2A KZ2E KZ3A KZ3E L L1 L2 Min OelTx P1 P2 P2A P2A-E P5 P5b P6 P7 P8 P9 P10 P11 P12 P13

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Description Using auxiliary power source (core 2 in) Using auxiliary power source (core 3 out) Using auxiliary power source (core 3 in) Mold position for core out (1) Mold position for core out (2) Mold position for core out (3) Priority for moving out (core 1) Priority for moving in (core 1) Priority for moving out (core 2) Priority for moving in (core 2) Priority for moving out (core 30 Priority for moving in (core 3) Shake as ejector (cores - number of times) Mold position for core in (1) Mold position for core in (2) Mold position for core in (3) Time dependent (core 1 out) Time dependent (core 1 in) Time dependent (core 2 out) Time dependent (core 2 in) Time dependent (core 3 out) Time dependent (core 3 in) Before mold opening (core 1 out) Before mold opening (core 2 out) Before mold opening (core 3 out) While mold is moving (core 1 out) While mold is moving (core 1 in) While mold is moving (core 2 out) While mold is moving (core 2 in) While mold is moving (core 3 out) While mold is moving (core 3 in) Retract position (ejector) Forward position (ejector) Shake position (ejector) Time (minutes) Oil temperature actual value Clamping pressure 1st mold protection pressure 2nd mold protection pressure 5 Mold protection pressures Nozzle forward pressure Holding (nozzle) pressure after injection Injection boost pressure 1st injection hold pressure 2nd injection hold pressure 3rd injection hold pressure 4th injection hold pressure, 5th injection hold pressure 6th injection hold pressure 7th injection hold pressure

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MAINTENANCE: Variable P14 P15 P16 P17 P18 P19 P20 P21 P25 P26 P30 P31 P32 P33 P34 P35 PF PFs PFu PFx PH PH3a PH3x PHs PHu PHx PNs PSs PSx PVs PVs SAx SD SFs SFx SKs SKs1 SKs2 SKx SKx1 SKx2 SSx Std StZ StZx SZ SZx V1 V2 V3

Description 8th injection hold pressure 9th injection hold pressure 10th injection hold pressure 1st back pressure 2nd back pressure 3rd back pressure 4th back pressure 5th back pressure Ejector forward pressure Ejector retract pressure Pressure core 1 out Pressure core 1 in Pressure core 2 out Pressure core 2 in Pressure core 3 out Pressure core 3 in Cavity pressure cut-off point Peak value of cavity pressure Cavity pressure at cut-off Cavity pressure actual value Hydraulic pressure cut-off point (boost to hold) Actual melt pressure,(special equipment) Peak melt pressure, (special equipment) Peak value of injection pressure Hydraulic pressure at cut-off Hydraulic pressure actual value Injection hold peak pressure Back pressure peak value Back pressure actual value Peak value of injection pressure (this abbrev. sometimes used) Peak Value of cavity pressure (this abbrev. sometimes used) Actual ejector position Actual nozzle position Mold opening stroke (stored), see Program Actual mold position Clamping force stored Clamping force stored (tiebar 1) Clamping force stored (tiebar 2) .....up to 4 Actual toggle position Clamping force current (tiebar 1) Clamping force current (tiebar 2) .....up to 4 Actual screw position Time (hours) Good parts required (set value Good parts required (actual value) Total cycles required Total cycles produced (actual value - excluding rejects) Clamp closing speed A to W3 Clamp closing speed W3 to W1 Clamp closing speed W1 to G2

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MAINTENANCE: Variable V4A-E V6 V7 V8 V9 V10 V11 V12 V13 V14 V15 V16 V17 V18 V19 V20 V21 V23 V24 V25 V26 V30 V31 V32 V33 V34 V35 VP2 VP2A VSchx W1 W2 W3 W4 Z1 Z2 Z3 Z4 Z4x Z5 Z5a Z6 ZA ZA1 ZA2 ZA3 ZAV ZD ZDx ZE1

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Description 5 Mold Protection speeds Clamp opening speed G2 to W4 Clamp opening speed W4 to W2 Clamp opening speed W2 to A Nozzle forward speed K to J1 Nozzle forward speed J1 to J Sprue break speed (J to K) 1st injection speed 2nd injection speed 3rd injection speed 4th injection speed 5th injection speed 6th injection speed 7th injection speed 8th injection speed 9th injection speed 10th injection speed Intrusion speed Decompression speed Ejector forward speed Ejector retract speed Speed (core 1 moving out) Speed (core 1 moving in) Speed (core 2 moving out) Speed (core 2 moving in) Speed (core 3 moving out) Speed (core 3 moving in) 1st mold protection speed 2nd mold protection speed Mold closing speed (actual value) Mold position at start of 3rd closing speed (between W3 and G1) Mold position at start of 3rd opening speed (between W4 and A) Mold position at start of 2nd closing speed (between A and W1) Mold position at start of 2nd opening speed (between A and W2) Injection boost time Injection hold time Screw feed delay time Cooling time Elapsed cooling time (also appears as 'ACT') Recycle time (time mold is open after ejection) Nozzle contact pressure time (delay before injection) Sprue break delay time Forward dwell (ejector) Moving out time (core 1) Moving out time (core 2) Moving out time (core 3) Forward delay (ejector) Screw feed time limit (A01) (Max - Min on A02) Elapsed feeding time (screw) Moving in time (core 1)

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MAINTENANCE: Variable ZE2 ZE3 ZF ZFx ZIN ZKV ZL1 ZL2 ZLV1 ZLV2 ZS0 ZS1 ZSx ZSZ ZU1 ZU2 ZU3 ZUa1 ZUa2 ZUa3 ZUs ZUx

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Description Moving in time (core 2) Moving in time (core 3) Mold protection time set value Mold protection time actual value Intrusion time Toggle lever lockup time (A01) Air blowing time (air valve 1) Air blowing time (air valve 2) Air blowing delay time (air valve 1) Air blowing delay time (air valve 2) Minimum injection time limit (A01) Minimum on A02 Maximum injection time limit (A01) Maximum on Ao2 Elapsed injection boost time Number of cycles interval between toggle lubrications Monitoring time (core 1 in) Monitoring time (core 2 in) Monitoring time (core 3 in) Monitoring time (core 1 out) Monitoring time (core 2 out) Monitoring time (core 3 out) Time taken for previous cycle Elapsed time of the current cycle (begins at start of mold close)

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MAINTENANCE: 17

GENERAL MACHINE CYCLE

Cycle Start - Mold Close If the mold is open to position A, the ejector is retracted to position L, and the screw is refilled to position C1, or C2 if decompression after screw refill has been selected, then the molding cycle will begin when the operator closes the front safety gate. The mold will close using the speeds chosen by the operator. The range of these speeds is also chosen by the operator by setting variables A, W3 and W1. It is better to use slower mold closing speeds when first setting up the machine and then increase the speeds later in order to reduce cycle time. Engel employs two different mold protection methods. The first method, now being phased out, uses a five-step mold protection zone. Mold protection begins at G1 and continues until G2 is reached. The mold is closed with high speed and pressure until the last closing speed (W1) before G1. The last closing speed is used to slow the mold down, so that the mold, as it enters the mold protection zone, is barely moving. During mold protection, the pressure is substantially reduced. If an obstacle is encountered, the pressure and sped are now so low that no or very little damage is incurred. The other factor to the mold protection zone is the time monitoring. Once a successful mold closing is achieved and the time taken to move through the mold protection zone (ZFx) can be noted. This time is set into the mold protection monitoring time (ZF). When the mold is prevented from closing by an obstruction, the machine continues to try and close, at reduced pressure and speed, until the monitoring time (ZF) is exceeded. The mold will then open and the cycle will stop. With the newly introduced "Autoprotect", the mold is closed with 100 % speed and pressure if so desired. In reality the speed is reduced going through the mold protection zone. From an initial successful closing, a monitoring curve is generated. Subsequent mold closings are compared to the monitoring curve. Either the force or speed of closing can be monitored. The operator sets a small tolerance to the monitoring curve and if an obstruction is encountered, the force will increase or the speed will decrease. Once the force or speed exceeds the monitoring curve by the set tolerance, the machine goes into mold protection alarm. This system is so sensitive that it can detect very small changes in speed or force and react very quickly to the change. Once the mold moves through the mold protection zone and the two mold halves touch, a "trigger" will be activated which will end mold protection pressure and will activate clamping pressure. Depending on the version of software existing within the machine control, the "trigger" could be an activated proximity switch input, an activated input from a series of limit switches, or when the mold, or toggle lever, reach a certain closing position. Toggle machines which are equipped with a Clampforce transducer, should always have clamping pressure set to 100 % since the controller will adjust the mold-height to deliver the correct clamp force. If you require a different clamp tonnage, change the clamp force set value and the machine will adjust automatically. On a direct hydraulic machine, reducing the clamp force set value will cause a proportional reduction in clamp force by reducing clamping pressure.

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MAINTENANCE: Carriage Forward When the mold is closed and in a locked position, the input signal B will be activated to signal the carriage to move forward. On direct hydraulic machines the G2 input is used to initiate the carriage forward movement. The carriage moves quickly at first, but then slows down near the end of its forward travel to avoid damaging the nozzle. The first speed is in effect from the sprue break point K, to point J1. The slowdown speed is in effect from point J1 to point J. J is the carriage zero point and indicates that the nozzle is pressed against the sprue bushing. To determine the extent of carriage forward pressure, turn the manual pressure gauge to position #4. At maximum this pressure can be 80% of full system pressure. As soon as the controller recognizes that the carriage is in its forward position, as indicated by the J marker, timer Z5a begins counting during which time the carriage forward pressure P5 is allowed to develop. When time Z5a expires, the injection process begins. Injection Boost The molder has up to 10 injection speeds and speed ranges available with which to profile the injection according to how quickly the mold will accept the plastic. Normally, the plastic is injected as quickly as possible and then transferred into hold pressure to complete mold cavity packing. Remember, that faster injection speeds, result in higher hydraulic injection pressures. This is particularly true when molding thin walled parts or when using molds that are equipped with very small gates. The molder must remember that injection speed control is only possible if the injection boost pressure limit P6 is set high enough to allow for that control. For example, with a speed profile set at 4 inches per second, an injection stroke of 2 inches should take about 0.5 seconds. However, if the elapsed injection time ZSx indicates that this injection took 2 seconds or an average rate of 1 inch per second, then clearly this machine is not achieving the required speed profile. As well, injecting this slowly can lead to all sorts of undesirable molding problems. The reason for this particular problem can be directly related to the incorrect setting of the injection boost pressure limit variable P6. On “open loop” machines, P6 is simply a hydraulic pressure relief valve setting which limits the maximum hydraulic injection pressure. On “closed loop” machines equipped with a Servo valve, the system pressure relief valve is set to 100% when the Servo valve is in operation. The pressure limitation is still controlled by P6, but the Servo valve limits pressure available to the injection piston, according to the P6 setting. Consider what is actually happening during the injection process. Assume that P6 is set at 2320 psi and hydraulic boost to hold cutoff is set to 1500 psi. Monitoring the manual pressure gauge position #3, or the variable PHx on the injection page, the actual hydraulic injection pressure can be observed. Notice that the actual injection pressure does not come near the 2320 psi setting. Instead, the pressure started at a very low level when the screw just started to move forward and then increased as the injection process continued.

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MAINTENANCE: A glance at the elapsed injection time ZSx also indicates that for this part, we had complete speed control. This injection stroke of 2 inches at a speed of 4 inches per second should have taken approximately 0.5 seconds.

INJECTION BOOST P6 - Injection Boost Pressure Limit

HOLD PRESSURE

P7-P16 Hold Pressures

PHx

0

Time PHx - Actual hydraulic pressure P6 - P16 - Relief or valve controlled pressure

You will notice that injection pressure increases over time. Also notice the constant value setting of P6 as an upper pressure limitation. If the actual hydraulic injection pressure does not approach the level of P6, speed control is maintained. As the screw moves forward, the mold cavity is filling. The fuller the mold cavity becomes, the more hydraulic pressure is required to inject plastic into the mold cavity. At this point you should be asking yourself why must P6 be set higher than the actual injection pressure required to fill the mold cavity? The answer lies in the fact that hydraulic pressure relief valves have a cracking pressure, at which they just start to crack open, which is lower than the actual full flow pressure relief valve setting. In other words, fluid will start relieving or cracking open the valve at about 80% of pressure relief valve setting. This will allow fluid to flow back to the oil tank and not to the injection piston which is trying to push the screw forward. Speed in hydraulics depends on how much fluid can be delivered to the injection piston in a given amount of time. Fluid which leaks through the relief valve is fluid lost, and the set injection speeds cannot be achieved. P6 is set correctly and speed is being controlled when increases in the value of P6 do not bring about any further reductions in the elapsed injection time, ZSx.

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MAINTENANCE: With the increase specific injection pressure program on the injection page switched to "No", the injection process occurs using a regenerative hydraulic circuit. This will provide a higher possible injection speed but with a proportional reduction in specific injection pressure. The regenerative circuit is possible by re-directing the rod side oil to be combined with the pump flow in order to supply more GPMs to the back side of the injection piston. This results in pressure being applied to both sides of the piston causing the net injection force to be lower. A faster injection speed, but a lower than possible specific injection pressure is the net effect. If you are having difficulty injecting plastic into the mold, it is possible to select the increased injection pressure function which would result in an increase to the specific injection pressure in front of the screw tip. When this function is chosen, the hydraulic oil from the piston's rod side is directed back to the oil reservoir. By eliminating the rod side pressure, the piston's forward force will increase and will cause an increase in specific injection pressure. Injection Hold Pressure When most of the plastic has been injected into the mold cavity, the molder must choose a means of switching from injection speed control into injection pressure control. In other words, from boost into hold pressure. Engel machines have up to five separate methods to initiate the transfer into hold pressure. The method by which the machine actually does transfer into hold pressure, will be indicated by a software flag to the right of the triggering variable. The operator can choose: 1. Time, as set by variable Z1, 2. Stroke position, as set by variable C3, 3. Hydraulic pressure, as set by variable PH, 4. Mold cavity pressure, as set by variable PF, or 5. Some external means as indicated by a digital input C3E. For example, the time variable Z1, could be set so that the machine will inject for the length of time Z1 and then transfer into hold pressure. Another method would be to set the stroke position, C3 so that the machine will inject until the stroke position C3 is reached and then transfer into hold pressure. For transfer based on hydraulic pressure, the variable PH would be set to a particular value and when the actual hydraulic pressure, PHx equals PH, the machine would transfer into hold pressure. In order to use this method effectively, variable C3b can be set to provide a switching window within which the controller would look for the required hydraulic pressure value. Typically, C3b is set slightly higher than the actual screw position at switch over. Since position C3b must be reached before the PH variable is considered by the controller, pressure peaks during injection will not cause a premature boost to hold transfer. For transfer based on mold cavity pressure, the variable PF would be set to a particular value and when the actual mold cavity pressure, PFx equals PF, the machine would transfer into hold pressure.

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MAINTENANCE: Of course, both the hydraulic pressure transfer and the mold cavity pressure transfer require that the machine be equipped with the proper pressure sensors. For a transfer based on a particular external indication, the function C3E must be switched to "YES". The machine will now inject until the external device delivers a digital input signal to the machine controller. An example of this type of device is a unit which measures the mold parting line distance. The injection proceeds until the mold parting line device indicates a certain cavity fill condition and then transmits a digital input signal to the machine controller causing the boost to hold transition. The variables PFu, PHu, C3u and ZSx on the injection page, also provide useful information on the boost to hold pressure function. For example, PFu indicates the actual mold cavity pressure at the moment of boost to hold transfer. PHu indicates the actual hydraulic pressure at the moment of boost to hold transfer. The variable C3u indicates the actual screw position at the moment of boost to hold transfer. ZSx indicates how long the injection took - from the start of the injection function, to the transfer into hold pressure. These values will appear no matter which method is employed. For example, if the machine is running on stroke position transfer, and you would like to change the transfer to occur based on hydraulic pressure, monitor variable PHu. Take the value that consistently comes up in PHu and enter that value into PH. The machine will now look for this level of hydraulic pressure before the transfer into hold pressure occurs. Remember though, you should also set the value of C3b in order to provide an appropriate switching window and also to guarantee that you are transferring on hydraulic pressure and not on the C3b stroke position value. If the hydraulic pressure transfer is operating correctly, you should now be witnessing a PHu value equal to PH and a C3u value indicating the screw position at transfer. The variables PFs and PVs indicate the peak values in cavity pressure and hydraulic pressure that occurred during the injection cycle. Once the machine has transferred into hold pressure, timer Z2 starts to run. Each of the separate hold pressures are maintained for one-tenth of Z2 time. For example, if Z2 was set to 10 seconds, each of the separate hold pressures would be maintained for one second. Generally, the first few hold pressures should equal the hydraulic injection pressure at the moment of boost to hold pressure transfer. The remaining hold pressures could then be profiled depending on the desired part quality. Switching from a higher actual injection pressure into a lower hold pressure will tend to allow plastic to flow out of the mold cavity and could lead to sink marks in the molded part. The material which lies ahead of the screw after injection, preventing the screw from bottoming out, is known as the cushion. The plastic cushion plays an important part in the molding process during hold pressure. The cushion provides the medium through which pressure is transmitted from the screw to the mold cavity. The cushion also provides a quantity of material which is available to be pushed into the mold cavity during packing and hold pressure in order to compensate for part shrinkage.

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1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

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MAINTENANCE: The cushion size is displayed after each injection cycle as variable CPx on the hold pressure page. The difference between C3u, the screw position at boost to hold pressure transfer, and CPx, represents the screw travel under hold pressure conditions. The extent and duration of hold pressure has a lot to do with the dimensional stability and outer appearance of the molded part. If hold pressure time is too short, the mold gates will not have had enough time to freeze off and sink marks could appear on the part. This is especially true of larger parts or when higher hold pressures are employed. After the mold gates "freeze", hold pressure has no effect and should be terminated at that point. Cooling - Screw Refill When the hold pressure time Z2 ends, the cooling time Z4 begins. For Z4 amount of time, the mold will remain closed allowing the part to solidify enough to be ejected when the mold opens. Generally, the lowest cycle times can be achieved using the lowest melt temperature and the lowest mold temperature possible. It must be recognized, however, that injecting relatively cool material into a relatively cool mold can also present problems. The trick is to find the best melt temperature and the best mold temperature for your specific molding purposes. For example, if the mold temperature is too low, injection can be difficult. An indication of this could show up as short shots or as dramatically increasing injection pressures, especially when molding thin walled parts. Notice also that it is during the cooling time that the screw refill function occurs. As the screw turns, frictional forces between the screw and the barrel melt the plastic granules. The screw flights force the melted plastic ahead of the screw in preparation for the next injection. As the screw is turning, it is the plastic gathering in front of the screw that causes the screw to travel backwards axially, as it turns. If we restrict the backwards travel of the screw by increasing the back pressure, this would cause an increase in the plastic melt temperature, a more densely packed shot, and a more homogeneous mixture of the plastic melt. During the screw refill function, it is important to remember that the melting process is partially governed by the rate at which the plastic will actually melt. A poor melt mixture can result using a very high screw refill speed that does not allow the plastic granules enough time to melt. As well, some plastics are extremely shear sensitive and can actually degrade at high screw refill speeds Each plastic has its own specific characteristics, but as a general rule , the best melting performance can usually be achieved using as slow a screw refill speed as possible. For example, if the cooling time is quite a bit longer than the screw refill time, does it does not make any sense to drive the screw motor at a 100% RPM rate. Of course, the major determinant here is the quality of the molded part. However, if a good quality part can be produced at a lower screw refill RPM rate, why not save the wear and tear on the machine and mold parts with a lower screw speed?

16/12/05

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

35

MAINTENANCE: It is also important to remember that the screw refill function has priority over the mold open function. For this reason, make sure that the screw refill function has been completed before the cooling time Z4 has expired. Otherwise, the machine will wait for the screw refill function to finish before allowing the mold to open. An indication of the screw speed being too low is when the actual cooling time is longer than the set value cooling time, Z4. After the screw has refilled for the next injection, it is sometimes necessary to decompress, or "suck back" the screw in order to prevent the plastic ahead of the screw from drooling. This function pulls back the plastic melt with a vacuum effect caused by the retracting injection screw. The distance of the decompression is set by variable C2 on the screw refill page. Some situations call for a decompression before the screw refill function and this distance can be set by variable C4 on the same page. The molder can also move the screw refill function to a later point in the cooling period by using the screw refill delay timer Z3. This function can be useful if the plastic material is very heat sensitive and there is a very long cooling time. Sprue Break After the screw has been refilled , the sprue break function will go into effect if it has been selected. Since the mold is relatively cool compared to the nozzle, a "freezing off" of the nozzle tip can occur. To prevent this condition, the nozzle is pulled back to the operator chosen sprue break position K and will wait at that position until the mold closes again in the next cycle. To guarantee that the sprue break function does not occur until after the screw refill and decompression functions have been completed, use the sprue break delay timer Z6 to ensure the correct sequence of events. If all of these functions have taken place, the machine controller is only waiting for the end of the cooling period in order to continue the cycle. Mold Open When the cooling time Z4 expires, the controller will start the mold open function. The mold will open at the speeds chosen by the operator. The range of these speeds is set by the operator by adjusting variables W4, W2 and A. It is better to use slower mold opening speeds when first setting up the machine and then increase the speeds later in order to reduce cycle time. The mold opens under a software set pressure until it reaches stroke position A. Ejection In the interests of decreasing cycle time, it is also possible to eject the part as the mold is opening rather than waiting for the full mold open position. However, this procedure is effective only when the machine is equipped with an extra pump or accumulator specifically dedicated to the “ejection on the fly” function. If the extra hydraulic equipment is not installed, the variable A1, Mold Position to Start Ejector, should be set equal to the mold open position A. Both of these variables can be found on the Ejector page. On earlier versions of software, A1 is located on the mold open page. If your machine incorporates a robot to remove the parts, it is possible to install mechanical stops so that the mold opens to the exact position every time. When the robot reaches in for the part, the mold will always be in the right position.

36

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

16/12/05

MAINTENANCE: As soon as the mold opens to the A position, the ejection function is signaled to begin. The ejector will move forward at an operator set speed and pressure from the rear position L, to the stroke position L1. Again, if you do not need high speeds and pressures to complete the ejection function, lower these variables. If the ejector forward dwell time ZA has been selected, the ejector will stay in the forward position for ZA amount of time and then return to the rear position. As well, the ejection function can be delayed after reaching the mold open position by setting the Ejector Forward Delay, ZAV, to a value greater than zero. If multiple ejections are required, it is not necessary on newer software to have the ejector return to the rear position before moving forward again. For example, if the variable L2, Ejector Shake Position was set between the ejector rear position L, and the ejector stroke position L1, the ejector would move forward to L1 and shake back and forth between L1 and L2 for the number of ejections required, and then return to the rear position. Re-Cycle Time (Mold Open Time) As soon as the ejector returns to the rear position at the end of the ejection function, the re-cycle time Z5 begins. If the variable Z5 is set greater than zero, the next cycle will not begin until the expiration of Z5 time. This timer is usually employed to guarantee that the part has had enough time to fall clear of the mold before the mold close function is activated. If the Z5 timer is used in conjunction with the ejection control option, a dual ejection function can be put into effect. The ejection control function is used to detect whether or not a molded part has been ejected and is clear of the mold. Ejection scales or a photocell determine if the molded part has fallen clear of the mold and if so, signals the next cycle to begin. If the signal is received during mold opening, indicating that the part has dropped out, there will be no ejection, but the cycle will continue. If the mold has opened without seeing the signal, the ejection function will operate but the controller must see the drop out signal within the re-cycle time Z5 to continue the cycle. For example, if the operator is employing an airblow to eject the part during mold open, the ejector can be employed as a back-up ejection system. The ejection control function can eliminate the need for hydraulic ejection and lead to significant cycle time savings. Cycle Repeats in Automatic If the mold is at position A, the ejector is at position L, and the screw is at position C1, or C2 if decompression after screw refill has been selected, then the molding cycle will continue.......

16/12/05

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

37

MAINTENANCE:

38

1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION

16/12/05

MAINTENANCE: 2. GENERAL MACHINE SPECIFICATIONS Engel Injection molding machines are designed using distinct modular elements for clamp, injection unit, electronics and hydraulics. The modular elements can be mixed to achieve a high degree of customization and also means a machine can be re-configured at a later time.

1

LEGEND FOR MACHINE SPECIFICATION TABLES. 1 2 3 4 5 6 7 8 (C) D. ft-lbs. g.p.m. h. HP Hz (Inj.) ins. ins3 K KW l. or L lbs. mm N/A ozs. p.s.i. R.P.M. tons w.

16/12/05

= = = = = = = = = = = = = = = = = = = = = = = = = = = = =

Based on polystyrene material. Based on HPDE material (for ES750+) Calculated. Can be increased with Accumulator. Can be increased. As per Euromap 6 standard. 30 mm Screw also available as standard. With increased injection pressure. Clamp weight. Diameter foot pounds (torque) gallons per minute. height Horse power Hertz (cycles per second) Injection weight. Inches. cubic inches. 1000 Kilowatts length. pounds. millimetres. Not Applicable. ounces. pounds per square inch. revolutions per minute. U.S. tons = 2000lbs. width.

2. GENERAL MACHINE SPECIFICATIONS

39

MAINTENANCE: 2

MACHINE SPECIFICATIONS

2.1

TOGGLE INJECTION MOLDING MACHINES

ES 100

ES 150

Clamp force

US tons

100

150

Clamp opening force

US tons

10

18 5.91 - 20.47

CLAMP

Clamp stroke (max)

inches

Mold height (min - max)

inches

12.20 9 9.84 - 20.87

Daylight (min - max)

inches

9.84 - 33.07

Platen size (H x V)

16.54

9

5.91 - 37.01

Standard - inches A

22.68x22.68

N/A

Extended - inches B

N/A

28.35x25.20

Distance between

Standard - inches A

15.98x15.98

N/A

tie bars (HxV)

Extended - inches B

N/A

19.69x16.54 2.95

Tie bar diameter

inches

2.36

Hydraulic ejector stroke

inches

3.94

5.12

tons

2.8

6.8

330

330

330

330

650

650

650

750

Screw diameter

mm

30

35

40

45

40

45

50

55

Screw diameter 1+3 Shot size

inches

Hydraulic ejector force INJECTION

1.181

1.378

1.575

1.772

1.575

1.772

1.969

2.165

oz

3.7

5.0

6.5

8.3

8.2

10.3

12.7

15.4

in3

6.9

9.4

12.3

15.5

15.3

19.4

24.0

29.0

oz/sec

0.5

0.8

0.9

1.2

0.8

1.1

1.5

1.6

lbs/hr

118

183

200

265

186

246

334

349

in3/sec

5.0

6.8

8.9

11.3

6.5

8.2

10.1

16.1

in3/sec

6.8

9.3

12.1

15.3

8.7

11.0

13.6

21.5

in/sec

4.6

4.6

4.6

4.6

3.3

3.3

3.3

4.4

Injection velocity (regenerative)

in/sec

6.2

6.2

6.2

6.2

4.5

4.5

4.5

5.8

Screw Stroke

inches

6.30

6.30

6.30

6.30

7.87

7.87

7.87

7.87

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press. 4 4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

Injection pressure (max)

psi

30000

30000

24143

21765

30000

27173

22011

22910

Injection pressure (regenerative)

psi

30000

23200

17763

16013

22418

20306

16448

17120

rpm

420

420

320

320

297

297

297

238

ft-lbs

260

260

325

325

514

514

514

813

23.3:1

20:1

17.5:1

15.6:1

20:1

24.2

24.2

31.7

Screw speed max (min = 25) 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force

inches US tons

9.84

13.78

5.2

7.6

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm US gal

24.0

24.0

24.0

24.0

24.2

52

113

230/460/575/ - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH)

kw sec gpm inches

20

30

3+Nozzle

4+Nozzle

7.2

12.7

30

40

13.7

15.7

16.7

8

8

11

1.7

1.6

6

8

165x52x80

219x67x86 16200

Machine weight

lbs

9500

Hopper capacity

lbs

44

163

ERC23

ERC33

Suitable Engel robots

30

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

40

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS TOGGLE INJECTION MOLDING MACHINES

ES 200

ES 250

Clamp force

US tons

200

250

Clamp opening force

US tons

CLAMP

25

33

inches

18.11

20.08

Mold height (min - max)

inches

5.91 - 22.05

7.87 - 24.02

Daylight (min - max)

inches

5.91 - 40.16

7.87 - 44.09

Standard - inches A

N/A

32.68x32.68

Extended - inches B

30.71x27.36

N/A

Distance between

Standard - inches A

N/A

22.44x22.44

tie bars (HxV)

Extended - inches B

Clamp stroke (max)

Platen size (H x V)

21.26x18.11

N/A

Tie bar diameter

inches

3.35

3.54

Hydraulic ejector stroke

inches

5.91

5.91

Hydraulic ejector force

tons

INJECTION

6.8

6.8

750

750

750

1050

750

1050

1050

45

50

55

60

45

50

55

60

1.772

1.969

2.165

2.362

1.772

1.969

2.165

2.362

oz

10.3

12.7

15.4

19.7

10.3

13.7

16.6

19.7

in3

19.4

24.0

29.0

37.1

19.4

25.8

31.2

37.1

oz/sec

0.9

1.2

1.6

2.0

0.9

1.2

1.6

2.0

lbs/hr

197

268

349

441

197

268

349

441

in3/sec

10.8

13.3

16.1

15.1

10.8

10.5

12.7

15.1

in3/sec

14.4

17.8

21.5

19.1

14.4

13.3

16.1

19.1

in/sec

4.4

4.4

4.4

3.4

4.4

3.4

3.4

3.4

Injection velocity (regenerative)

in/sec

5.8

5.8

5.8

4.4

5.8

4.4

4.4

4.4

Screw Stroke

inches

7.87

7.87

7.87

8.46

7.87

8.46

8.46

8.46

Screw diameter

mm

Screw diameter 1+3 Shot size

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

1050

Injection pressure (max)

psi

30000

27695

22910

20518

30000

27695

22910

20518

Injection pressure (regenerative)

psi

22418

20696

17120

16154

22418

21805

18037

16154

rpm

238

238

238

238

238

238

238

238

ft-lbs

813

813

813

813

813

813

813

813

31.7

31.7

31.7

Screw speed max (min = 25) 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force

inches US tons

20:1

20:1

13.78

13.78

7.6

7.6

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

31.7

US gal

125

125

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

40

40

31.7

31.7

31.7

31.7

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

4+Nozzle

4+Nozzle

kw

13.7

sec

1.8

1.9

gpm

11

11

inches lbs lbs

15.7

16.7

18.7

13.7

15.7

245x70x86

245X70X89

21600

23000

163

163

ERC33-43

ERC43

16.7

18.7

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

41

MAINTENANCE: MACHINE SPECIFICATIONS TOGGLE INJECTION MOLDING MACHINES

ES 200

ES 250

Clamp force

US tons

200

250

Clamp opening force

US tons

CLAMP

25

33

Clamp stroke (max)

inches

18.11

20.08

Mold height (min - max)

inches

5.91 - 22.05

7.87 - 24.02

Daylight (min - max)

inches

5.91 - 40.16

7.87 - 44.09

Standard - inches A

N/A

32.68x32.68

Extended - inches B

30.71x27.36

N/A

Distance between

Standard - inches A

N/A

22.44x22.44

tie bars (HxV)

Extended - inches B

21.26x18.11

N/A

Platen size (H x V)

Tie bar diameter

inches

3.35

3.54

Hydraulic ejector stroke

inches

5.91

5.91

Hydraulic ejector force

tons

6.8

6.8

750

750

750

1050

750

1050

1050

1050

45

50

55

60

45

50

55

60

1.772

1.969

2.165

2.362

1.772

1.969

2.165

2.362

oz

10.3

12.7

15.4

19.7

10.3

13.7

16.6

19.7

in3

19.4

24.0

29.0

37.1

19.4

25.8

31.2

37.1

oz/sec

0.9

1.2

1.6

2.0

0.9

1.2

1.6

2.0

lbs/hr

197

268

349

441

197

268

349

441

in3/sec

10.8

13.3

16.1

15.1

10.8

10.5

12.7

15.1

in3/sec

14.4

17.8

21.5

19.1

14.4

13.3

16.1

19.1

in/sec

4.4

4.4

4.4

3.4

4.4

3.4

3.4

3.4

Injection velocity (regenerative)

in/sec

5.8

5.8

5.8

4.4

5.8

4.4

4.4

4.4

Screw Stroke

inches

7.87

7.87

7.87

8.46

7.87

8.46

8.46

8.46

INJECTION Screw diameter

mm

Screw diameter 1+3 Shot size

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

Injection pressure (max)

psi

30000

27695

22910

20518

30000

27695

22910

20518

Injection pressure (regenerative)

psi

22418

20696

17120

16154

22418

21805

18037

16154

rpm

238

238

238

238

238

238

238

238

ft-lbs

813

813

813

813

813

813

813

813

31.7

31.7

31.7

Screw speed max (min = 25) 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force

inches US tons

20:1

20:1

13.78

13.78

7.6

7.6

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

31.7

US gal

125

125

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

40

40

31.7

31.7

31.7

31.7

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

4+Nozzle

4+Nozzle

kw

13.7

sec

1.8

1.9

gpm

11

11

inches lbs lbs

15.7

16.7

18.7

13.7

15.7

245x70x86

245X70X89

21600

23000

163

163

ERC33-43

ERC43

16.7

18.7

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

42

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS TOGGLE INJECTION MOLDING MACHINES

ES 300

CLAMP Clamp force

US tons 300

Clamp opening force

US tons 42

ES 400

ES 450

400

450

57

57

Clamp stroke (max)

inches 23.62

27.56

27.56

Mold height (min - max)

inches 7.87 - 25.98

11.81 - 33.94

11.81 - 33.94

Daylight (min - max)

inches 7.87 - 49.60

11.81 - 61.50

11.81 - 61.50

44.56x44.56

N/A

Platen size (H x V)

Standard - inches A

35.67x35.87

Extended - inches B

N/A

N/A

47.24x47.24

Distance between

Standard - inches A

25.04x25.04

30.00x30.00

N/A

tie bars (HxV)

Extended - inches B

N/A

N/A

33.07x33.07

Tie bar diameter

inches 3.94

5.51

5.51

Hydraulic ejector stroke

inches 7.87

9.45

9.45

Hydraulic ejector force

tons 8.9

8.9

8.9

1350

1800

2050

2050

2550

2050

2050

2550

60

70

60

70

80

60

70

80

2.362

2.756

2.362

2.756

3.150

2.362

2.756

3.150

oz 20.0

23.8

33.7

27.5

37.5

50.5

27.5

37.5

50.5

in3 37.7

44.9

63.4

51.8

70.5

95.1

51.8

70.5

95.1

oz/sec 1.4

1.8

2.7

2.2

3.2

3.0

2.2

3.2

3.0

lbs/hr 318

402

603

485

728

683

485

728

683

in3/sec 13.9

16.6

18.8

16.4

22.4

24.9

16.4

22.4

24.9

in3/sec 17.3

20.6

22.6

19.7

26.9

29.2

19.7

26.9

29.2

in/sec 3.8

3.8

3.1

3.8

3.8

3.2

3.8

3.8

3.2

Injection velocity (regenerative)

in/sec 4.7

4.7

3.8

4.5

4.5

3.8

4.5

4.5

3.8

Screw Stroke

inches 10.24

10.24

10.63

11.81

11.81

12.20

11.81

11.81

12.20

Injection pressure (max)

psi 28304

26535

22780

30000

25810

23751

30000

25810

23751

Injection pressure (regenerative)

psi 22850

21421

18934

24979

21491

20205

24979

21491

20205

rpm 217

217

217

262

262

175

8

262

262

175

ft-lbs 1305

1305

1305

1305

1305

1950

8

1305

1305

1950

58.1

58.1

1350

INJECTION Screw diameter

mm 55

Screw diameter 1+3 Shot size

inches 2.165

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

Screw speed max (min = 25) 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force

20:1 inches 19.69 US tons 12.4

20:1

20:1

25.59

25.59

12.4

12.4

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm 46.0

46.0

46.0

US gal 145

58.1

58.1

58.1

58.1

204

204

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

60

60

ELECTRICS Power supply available Total rated horsepower

volts 230/460/575 - 3Ph/60Hz HP 50

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

4+Nozzle kw 20.2

4+Nozzle 21.7

24.7

25.3

4+Nozzle 29.4

33.5

25.3

29.4

sec 2.0

2.6

gpm 14

17

17

345x88x101

345x88x101

49000

49000

inches 284X72X91 lbs

27000

lbs 163 ERC43-63

33.5

2.6

163

163

ERC53-63

ERC-53-63

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

43

MAINTENANCE: MACHINE SPECIFICATIONS TOGGLE INJECTION MOLDING MACHINES

ES 500

ES 500W

ES 500W

Clamp force

US tons

500

500

500

Clamp opening force

US tons

CLAMP

60

60

60

Clamp stroke (max)

inches

27.56

27.56

27.56

Mold height (min - max)

inches

11.81 - 33.94

11.81 - 33.94

11.81 - 33.94

Daylight (min - max)

inches

11.81 - 61.50

11.81 - 61.50

11.81 - 61.50

Standard - inches A

47.80x47.24

58.26x47.24

58.26x47.24

Extended - inches B

N/A

N/A

N/A

Distance between

Standard - inches A

34.65x33.07

44.09x33.07

44.09x33.07

tie bars (HxV)

Extended - inches B

N/A

N/A

N/A

Platen size (H x V)

Tie bar diameter

inches

5.51

5.51

5.51

Hydraulic ejector stroke

inches

9.45

9.45

9.45

8.9

8.9

Hydraulic ejector force

tons

INJECTION Screw diameter

mm

Screw diameter

inches

Shot size

1+3

8.9

2550

2550

2550

2550

2550

2550

3550

3550

3550

70

80

85

70

80

85

70

80

90

2.756

3.150

3.346

2.756

3.150

3.346

2.756

3.150

3.543

oz

38.7

50.5

57.1

38.7

50.5

57.1

48.7

63.6

80.5

in3

151.4

72.8

95.1

107.3

72.8

95.1

107.3

91.6

119.6

oz/sec

3.2

3.0

3.6

3.2

3.0

3.6

1.9

2.6

2.7

lbs/hr

728

683

820

728

683

820

417

585

597

in3/sec

19.0

24.9

28.1

19.0

24.9

28.1

18.0

23.6

29.8

in3/sec

22.4

29.2

33.0

22.4

29.2

33.0

21.2

27.6

35.0

in/sec

3.2

3.2

3.2

3.2

3.2

3.2

3.0

3.0

3.0

in/sec

3.8

3.8

3.8

3.8

3.8

3.8

3.5

3.5

3.5

inches

12.20

12.20

12.20

12.20

12.20

12.20

15.35

15.35

15.35

Injection pressure (max)

psi

30000

23751

21039

30000

23780

22639

psi

25521

20205

21039 30000 17898 25521

23751

Injection pressure (regenerative)

20205

17898

25560

20260

19288

rpm

262

175

150

150

150

ft-lbs

1305

1950

2655

2655

2655

58.1

58.1

Injection capacity Recovery rate

1+2+3

Plasticizing capacity

1+2+3

Injection rate at max. press.

4

Injection rate (regenerative)

4

Injection velocity at max. press.

4

Injection velocity (regenerative)

4

Screw Stroke

Screw speed max (min = 25) Screw torque

5

Screw L/D ratio

8

175 8

20:1

Nozzle stroke

262

1950 8 1305 20:1

175

8

1950

175 8

8

1950

8

20:1

25.59

25.59

23.62

US tons

12.4

12.4

16.8

gpm

58.1

US gal

204

204

204

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

60

60

inches

Nozzle force

8

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

58.1

58.1

58.1

58.1

58.1

58.1

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Total heating wattage

75

4+N

4+N

5+N

4+N

4+N

5+N

5+Nozzle

kw

29.4

33.5

51.8

29.4

33.5

51.8

30.6

sec

2.6

2.6

2.6

gpm

17

17

21

349x88x101

353x99x101

365x99x102

Number of heat control zones

33.6

38.8

GENERAL Dry cycle performance

6

Water requirements (max) Machine dimensions (LxWxH)

inches

Machine weight

lbs

55200

60200

69000

Hopper capacity

lbs

163

163

300

ERC53-63

ERC63

ERC-63

Suitable Engel robots

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

44

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS

2.2

TIEBARLESS INJECTION MOLDING MACHINES

ES40TL

ES60TL

ES100TL

Clamp force

US tons

40

60

100

Clamp opening force

US tons

CLAMP

2.2

3.0

4.0

Clamp stroke (max)

inches

13.78

13.00

17.72

Mold height (min - max)

inches

7.09 - N/A

7.48 - N/A

9.84 - N/A

Daylight (min - max)

inches

7.09 - 20.87

7.48 - 20.47

9.84 - 27.56

21.65 x 16.93

25.60 x 16.93

27.95 x 22.05

3.94

3.94

3.94

2.9

3.5

Platen size (H x V)

Standard - inches A

see platen illustration below for max. mold size Hydraulic ejector stroke

inches

Hydraulic ejector force

tons

INJECTION Screw diameter

mm

Screw diameter

inches

Shot size

1+3

Injection capacity Recovery rate

1+2+3

Plasticizing capacity

1+2+3

Injection rate at max. press.

4

Injection rate (regenerative)

4

Injection velocity at max. press.

4

Injection velocity (regenerative)

4

Screw Stroke Injection pressure (max)

5

Injection pressure (regenerative) Screw speed max (min = 25) Screw torque 5

5

80

200

200

200

330

330

330

330

18

22

25

25

30

35

30

35

40

45 1.772

0.709

0.866

0.984

0.984

1.181

1.378

1.181

1.378

1.575

0.8

1.2

1.6

2.2

3.2

4.4

3.7

5.0

6.5

8.3

in3

1.5

2.3

3.0

4.2

6.0

8.2

6.9

9.4

12.3

15.5 1.2

oz/sec

0.1

0.2

0.3

0.4

0.6

0.9

0.5

0.8

0.9

lbs/hr

22

47

66

88

135

209

118

183

200

265

in3/sec

2.1

3.2

4.1

3.9

5.6

7.6

5.0

6.8

8.9

11.3

in3/sec

2.8

4.1

5.3

5.9

8.5

11.6

6.8

9.3

12.1

15.3

in/sec

5.4

5.4

5.4

5.1

5.1

5.1

4.6

4.6

4.6

4.6

in/sec

7.0

7.0

7.0

7.8

7.8

7.8

6.2

6.2

6.2

6.2

inches

3.90

3.90

3.90

5.51

5.51

5.51

6.30

6.30

6.30

6.30

psi

30000

30000

23200

30000

30000

23505

30000

30000

24143

21765

psi

30000

23200

17763

30000

21040

15456

30000

23200

17763

16013

rpm

360

360

360

480

480

480

420

420

320

320

ft-lbs

163

163

163

163

163

163

260

260

325

325

22:1

18.2:1

16:1

24:1

20:1

17.1:1

23.3:1

20:1

17.5:1

15.6:1

24.0

24.0

24.0

inches

Nozzle force

80

oz

Screw L/D ratio Nozzle stroke

4.3

80

US tons

7.87

7.87

9.84

3.2

3.2

5.3

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm US gal

10.6

10.6

10.6

30

16.1

16.1

16.1

57

24.0 60

ELECTRICS Power supply available

volts

230/460/575/ - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

230/460/575/ - 3Ph/60Hz

Total rated horsepower

HP

10

20

20

kw

3.2

sec

Number of heat control zones Total heating wattage

3+Nozzle

3+Nozzle

3+Nozzle

4.8

7.2

1.5

1.5

1.5

3

6

6

121x53x75

146x56x76

165x56x77

4846 44

9600 44

14000 44

ERSE21, ERC23

ERSE21, ERC23

ERSE21, ERC23

3.6

3.6

GENERAL Dry cycle performance

6

Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel Robots

gpm inches lbs lbs

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

45

MAINTENANCE: MACHINE SPECIFICATIONS TIEBARLESS INJECTION MOLDING MACHINES

ES150TL

ES200TL

Clamp force

US tons

150

200

Clamp opening force

US tons

CLAMP

9.8

9.8

Clamp stroke (max)

inches

23.62

27.56

Mold height (min - max)

inches

9.84 - N/A

9.84 - N/A

Daylight (min - max)

inches

9.84 - 33.46

9.84 - 37.40

33.46 x 27.56

35.43 x 29.53

5.90

5.90

Platen size (H x V)

Standard - inches A

see platen illustration below for max. mold size Hydraulic ejector stroke

inches

Hydraulic ejector force

tons

6.9

6.9

650

650

650

750

750

750

750

1050

40

45

50

55

45

50

55

60

1.575

1.772

1.969

2.165

1.772

1.969

2.165

2.362

oz

8.2

10.3

12.7

15.4

10.3

12.7

15.4

19.7

in3

15.3

19.4

24.0

29.0

19.4

24.0

29.0

37.1

oz/sec

0.8

1.1

1.5

1.6

0.9

1.2

1.6

2.0

lbs/hr

186

246

334

349

197

268

349

441

in3/sec

6.5

8.2

10.1

16.1

10.8

13.3

16.1

15.1

in3/sec

8.7

11.0

13.6

21.5

14.4

17.8

21.5

19.1

in/sec

3.3

3.3

3.3

4.4

4.4

4.4

4.4

3.4

Injection velocity (regenerative)

in/sec

4.5

4.5

4.5

5.8

5.8

5.8

5.8

4.4

Screw Stroke 5 Injection pressure (max)

inches

7.87

7.87

7.87

7.87

7.87

7.87

7.87

8.46

psi

30000

27173

22011

22910

30000

27695

22910

20518

psi

22418

20306

16448

17120

22418

20696

17120

16154

rpm

297

297

297

238

238

238

238

238

ft-lbs

514

514

514

813

813

813

813

813

31.7

31.7

31.7

INJECTION Screw diameter

mm

Screw diameter 1+3 Shot size

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

Injection rate (regenerative)4 Injection velocity at max. press.

4

4

5

Injection pressure (regenerative) Screw speed max (min = 25) Screw torque5 Screw L/D ratio Nozzle stroke Nozzle force

inches US tons

20:1

20:1

13.78

13.78

7.6

7.6

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

24.2

US gal

116

24.2

24.2

31.7

31.7 116

ELECTRICS Power supply available

volts

Total rated horsepower

HP

GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel Robots

30

230/460/575 - 3Ph/60Hz

30

30

40

40

13.7

15.7

16.7

13.7

6

6

9

4+Nozzle

Number of heat control zones Total heating wattage

230/460/575 - 3Ph/60Hz

kw

12.7

sec

2.0

gpm inches lbs lbs

6

4+Nozzle 15.7

16.7

18.7

2.0 9

221x71x89 19850 163

229x73x89 25350 163

ERSE31, ERC33

ERSE31, ERC33-43

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

46

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS TIEBARLESS INJECTION MOLDING MACHINES

ES300TL

ES400TL

Clamp force

US tons

300

400

Clamp opening force

US tons

CLAMP

17.8

23.0

Clamp stroke (max)

inches

33.50

37.40

Mold height (min - max)

inches

13.78 - N/A

13.78 - N/A

Daylight (min - max)

inches

13.78 - 47.24

13.78 - 51.18

46.46 x 35.43

55.12 x 42.52

7.87

9.84

Platen size (H x V)

Standard - inches A

see platen illustration below for max. mold size Hydraulic ejector stroke

inches

Hydraulic ejector force

tons

INJECTION Screw diameter

mm

Screw diameter Shot size 1+3

inches oz

Injection capacity Recovery rate 1+2+3 Plasticizing capacity

Injection rate at max. press.4 Injection rate (regenerative)4 Injection velocity at max. press.

4

8.9

1350

1350

1800

2050

2050

2550

55

60

70

60

70

80

2.165

2.362

2.756

2.362

2.756

3.150

20.0

23.8

33.7

27.5

37.5

50.5 95.1

37.7

44.9

63.4

51.8

70.5

oz/sec

1.4

1.8

2.7

2.2

3.2

3.0

lbs/hr

318

402

603

485

728

683

in3/sec

13.9

16.6

18.8

16.4

22.4

24.9

in3 1+2+3

8.9

in3/sec

17.3

20.6

22.6

19.7

26.9

29.2

in/sec

3.8

3.8

3.1

3.8

3.8

3.2

Injection velocity (regenerative)4

in/sec

4.7

4.7

3.8

4.5

4.5

3.8

Screw Stroke Injection pressure (max)5

inches

10.24

10.24

10.63

11.81

11.81

12.20

Injection pressure (regenerative)5 Screw speed max (min = 25) Screw torque5

psi

28304

26535

22780

30000

25810

23751

psi

22850

21421

18934

24979

21491

20205

rpm

217

217

217

262

262

175

ft-lbs

1305

1305

1305

1305

1305

1950

58.1

58.1

Screw L/D ratio Nozzle stroke

20:1

20:1

19.69

25.59

US tons

12.4

12.4

gpm

46.0

US gal

140

204

230/460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

inches

Nozzle force

8 8

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

46.0

46.0

58.1

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage GENERAL Dry cycle performance6 Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel Robots

50

60

4+Nozzle

4+Nozzle

kw

20.2

sec

2.2

3.2

gpm

12

12

273x83x101 35000/13000 163

315x88x101 55000/14000 163

ERSE41, ERC43-63

ERSE51, ERC53-63

inches lbs lbs

21.7

24.7

25.3

29.4

33.5

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

47

MAINTENANCE: MACHINE SPECIFICATIONS

2.3

VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES55VHRB

CLAMP Clamp force

US tons

55

Clamp opening force

US tons

2

Clamp stroke (max)

inches

Mold height (min - max)

inches

11.81 7 11.02

Daylight (min - max)

inches

11.02

Platen size (H x V)

inches

21.65 x 13.23

7

-N/A -22.83

ROTARY TABLE Rotary Table Diameter

inches

38.39

Mold pitch circle diameter

inches

20.87

Hydraulic ejector stroke

inches

5.0

Ejector penetration (above table)

inches

2.0

US tons

1.3 200

200

200

330

330

330

330

Screw diameter

mm

25

30

35

30

35

40

45

Screw diameter 1+2 Shot size

inches

Hydraulic ejector force INJECTION

Injection capacity 1+2 Recovery rate Plasticizing capacity

1+2

Injection rate at max. press.

3+4

3+4

Injection rate (regenerative)

Injection velocity at max. press.

3+4

0.984

1.181

1.378

1.181

1.378

1.575

1.772

oz

2.2

3.2

4.4

3.7

5.0

6.5

8.3

in3

4.2

6.0

8.2

6.9

9.4

12.3

15.5

oz/sec

0.4

0.6

0.9

0.5

0.8

0.9

1.2

lbs/hr

88

135

209

118

183

200

265

in3/sec

3.9

5.6

7.7

5.0

6.8

8.9

11.3

in3/sec

5.9

8.6

11.6

6.8

9.3

12.1

15.3 4.6

in/sec

5.1

5.1

5.1

4.6

4.6

4.6

Injection velocity (regenerative)

in/sec

7.8

7.8

7.8

6.2

6.2

6.2

6.2

Screw Stroke 4 Injection pressure (max)

inches

5.51

5.51

5.51

6.30

6.30

6.30

6.30

psi

30000

30000

23505

30000

30000

24143

21765

psi

30000

21040

15455

30000

23200

17763

480

480

480

420

420

320

6

320

6

6

325

6

3+4

4

Injection pressure (regenerative) Screw speed max (min = 25) 4 Screw torque

rpm ft-lbs

163

163

163

24:1

20:1

17.1:1

inches

13.0

13.0

inches

3.0

5.0

US tons

1.7

2.8

5.0 - 12.0

5.0 - 12.0

Screw L/D ratio Nozzle stroke Nozzle reach to mold centre Nozzle force 4 Nozzle height (min-max)

inches

16013

260

260

325

23.3:1

20:1

17.5:1

15.6:1

24.0

24.0

24.0

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

16.1

US gal

106

16.1

16.1

24.0 106

ELECTRICS Power supply available

volts

230/460/575/ - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

Total rated horsepower

HP

30

30

3+Nozzle

3+Nozzle

kw

4.8

7.2

Number of heat control zones Total heating wattage GENERAL Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

gpm inches lbs lbs

6

6

129 x 106 x 118 17000

129 x 106 x 118 17000

44

44

ERC23, ERV21, ERSE21

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

48

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES85VHRB

CLAMP Clamp force

US tons

85

Clamp opening force

US tons

4

Clamp stroke (max)

inches

Mold height (min - max)

inches

11.81 7 11.02

Daylight (min - max)

inches

11.02

Platen size (H x V)

inches

21.65 x 13.23

Rotary Table Diameter

inches

38.39

Mold pitch circle diameter

inches

20.87

Hydraulic ejector stroke

inches

5.0

Ejector penetration (above table)

inches

2.0

US tons

1.3

7

-N/A -22.83

ROTARY TABLE

Hydraulic ejector force INJECTION

200

200

200

330

330

330

330

25

30

35

30

35

40

45

0.984

1.181

1.378

1.181

1.378

1.575

1.772

oz

2.2

3.2

4.4

3.7

5.0

6.5

8.3 15.5

Screw diameter

mm

Screw diameter Shot size 1+2

inches

Injection capacity 1+2 Recovery rate Plasticizing capacity

1+2

Injection rate at max. press.

3+4

3+4

Injection rate (regenerative)

Injection velocity at max. press.

3+4

in3

4.2

6.0

8.2

6.9

9.4

12.3

oz/sec

0.4

0.6

0.9

0.5

0.8

0.9

1.2

lbs/hr

88

135

209

118

183

200

265

in3/sec

3.9

5.6

7.7

5.0

6.8

8.9

11.3

in3/sec

5.9

8.6

11.6

6.8

9.3

12.1

15.3 4.6

in/sec

5.1

5.1

5.1

4.6

4.6

4.6

Injection velocity (regenerative)

in/sec

7.8

7.8

7.8

6.2

6.2

6.2

6.2

Screw Stroke 4 Injection pressure (max)

inches

5.51

5.51

5.51

6.30

6.30

6.30

6.30

psi

30000

30000

23505

30000

30000

24143

21765

psi

30000

21040

15455

30000

23200

17763

480

480

480

420

420

320

6

320

6

6

325

6

3+4

Injection pressure (regenerative)4 Screw speed max (min = 25) 4 Screw torque

rpm ft-lbs

Screw L/D ratio Nozzle stroke Nozzle reach to mold centre Nozzle force 4 Nozzle height (min-max)

163

163

163

260

260

325

24:1

20:1

17.1:1

23.3:1

20:1

17.5:1

15.6:1

24.0

24.0

24.0

inches

13.0

13.0

inches

3.0

5.0

US tons

1.7

2.8

5.0 - 12.0

5.0 - 12.0

inches

16013

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

16.1

US gal

106

16.1

16.1

24.0 106

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

30

30

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage

kw

3+Nozzle

3+Nozzle

4.8

7.2

GENERAL Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

gpm inches lbs lbs

6

6

129 x 106 x 118 17000

129 x 106 x 118 17000

44

44

ERC23, ERV21, ERSE21

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

49

MAINTENANCE: MACHINE SPECIFICATIONS VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES125VHRB

CLAMP Clamp force

US tons

125

Clamp opening force

US tons

10

Clamp stroke (max)

inches

Mold height (min - max)

inches

15.75 7 15.75

-N/A

Daylight (min - max)

inches

15.757

-31.50

Platen size (H x V)

inches

31.89 x 17.72

Rotary Table Diameter

inches

46.46

Mold pitch circle diameter

inches

25.59

Hydraulic ejector stroke

inches

6.3

Ejector penetration (above table)

inches

3.1

US tons

1.8

ROTARY TABLE

Hydraulic ejector force INJECTION Screw diameter

mm

Screw diameter Shot size 1+2

inches

Injection capacity 1+2 Recovery rate Plasticizing capacity

1+2

Injection rate at max. press.

3+4

Injection rate (regenerative) 3+4 Injection velocity at max. press. 3+4 Injection velocity (regenerative)

3+4

Screw Stroke Injection pressure (max)

4

Injection pressure (regenerative) Screw speed max (min = 25) Screw torque

4

4

330

330

330

330

600

600

600

600

700

700

700

700

30

35

40

45

40

45

50

55

45

50

55

60 2.362

1.181

1.378

1.575

1.772

1.575

1.772

1.969

2.165

1.772

1.969

2.165

oz

3.7

5.0

6.5

8.3

8.2

10.3

12.7

15.4

10.3

12.7

15.4

18.3

in3

6.9

9.4

12.3

15.5

15.3

19.4

24.0

29.0

19.4

24.0

29.0

34.5

oz/sec

0.5

0.8

0.9

1.2

0.8

1.1

1.5

1.9

0.9

1.2

1.6

2.0

lbs/hr

118

183

200

265

186

246

334

435

197

268

349

441

in3/sec

5.0

6.8

8.9

11.3

6.4

8.2

10.1

10.9

9.2

11.4

13.8

13.7

in3/sec

6.8

9.3

12.1

15.3

8.7

11.1

13.7

14.2

12.0

14.8

17.9

17.0

in/sec

4.6

4.6

4.6

4.6

3.3

3.3

3.3

2.9

3.7

3.7

3.7

3.1

in/sec

6.2

6.2

6.2

6.2

4.5

4.5

4.5

3.8

4.9

4.9

4.9

3.9

inches

6.30

6.30

6.30

6.30

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

psi

30000

30000

24143

21765

30000

27164

22017

20420

5

30000

24708

20420

20509

5

psi

30000

23200

17763

16013

22129

20037

16240

15646

5

22986

18931

15646

16498

5

rpm

420

420

320

6

320

6

297

297

297

297

238

238

238

238

ft-lbs

260

260

325

6

325

6

514

514

514

514

813

813

813

813

23.3:1

20:1

17.5:1

31.4

31.4

Screw L/D ratio

15.6:1

20:1

20:1

Nozzle stroke

inches

13.0

15.8

15.8

Nozzle reach to mold centre

inches

5.0

5.0

5.0

US tons

2.8

4.0

4.0

5.0 - 12.0

5.0 - 12.0

5.0 - 12.0

Nozzle force Nozzle height (min-max)

4

inches

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

24.0

US gal

106

24.0

24.0

24.0

106

24.8

24.8

24.8

24.8

106

31.4

31.4

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

30

30

40

3+Nozzle

4+Nozzle

7.2

9.1

9

10

11

135 x 106 x 121 32000

174 x 106 x 121 33000

174 x 106 x 121 33000

44

163

163

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage

kw

10.7

4+Nozzle 11.7

13.1

10.7

11.7

13.1

15.9

GENERAL Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

gpm inches lbs lbs

ERC33, ERV31, ERSE31

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

50

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES150VHRB

CLAMP Clamp force

US tons

150

Clamp opening force

US tons

14

Clamp stroke (max)

inches

Mold height (min - max)

inches

15.75 7 15.75

Daylight (min - max)

inches

15.75

Platen size (H x V)

inches

31.89 x 17.72

Rotary Table Diameter

inches

46.46

Mold pitch circle diameter

inches

25.59

Hydraulic ejector stroke

inches

6.3

Ejector penetration (above table)

inches

3.1

US tons

1.8

7

-N/A -31.50

ROTARY TABLE

Hydraulic ejector force INJECTION Screw diameter

mm

Screw diameter

inches

Shot size

1+2

Injection capacity Recovery rate

1+2

Plasticizing capacity

1+2

Injection rate at max. press.

3+4

Injection rate (regenerative)

3+4

Injection velocity at max. press.

3+4

Injection velocity (regenerative)

3+4

Screw Stroke Injection pressure (max)

4

Injection pressure (regenerative) Screw speed max (min = 25) Screw torque

4

4

330

330

330

330

600

600

600

600

700

700

700

30

35

40

45

40

45

50

55

45

50

55

60

1.181

1.378

1.575

1.772

1.575

1.772

1.969

2.165

1.772

1.969

2.165

2.362

oz

3.7

5.0

6.5

8.3

8.2

10.3

12.7

15.4

10.3

12.7

15.4

18.3

in3

6.9

9.4

12.3

15.5

15.3

19.4

24.0

29.0

19.4

24.0

29.0

34.5

oz/sec

0.5

0.8

0.9

1.2

0.8

1.1

1.5

1.9

0.9

1.2

1.6

2.0

lbs/hr

118

183

200

265

186

246

334

435

197

268

349

441

in3/sec

5.0

6.8

8.9

11.3

6.4

8.2

10.1

10.9

9.2

11.4

13.8

13.7

in3/sec

6.8

9.3

12.1

15.3

8.7

11.1

13.7

14.2

12.0

14.8

17.9

17.0

in/sec

4.6

4.6

4.6

4.6

3.3

3.3

3.3

2.9

3.7

3.7

3.7

3.1

in/sec

6.2

6.2

6.2

6.2

4.5

4.5

4.5

3.8

inches

6.30

6.30

6.30

6.30

7.87

7.87

7.87

7.87

4.9

4.9

4.9

3.9

7.87

7.87

7.87

7.87

30000

24708

20420

20509

5

22986

18931

15646

16498

5

psi

30000

30000

24143

21765

30000

27164

22017

20420

5

psi

30000

23200

17763

16013

22129

20037

16240

15646

5

rpm

420

420

320

6

320

6

297

297

297

297

238

238

238

238

ft-lbs

260

260

325

6

325

6

514

514

514

514

813

813

813

813

23.3:1

20:1

17.5:1

31.4

31.4

31.4

Screw L/D ratio

15.6:1

20:1

20:1

Nozzle stroke

inches

13.0

15.8

15.8

Nozzle reach to mold centre

inches

5.0

5.0

5.0

US tons

2.8

4.0

4.0

5.0 - 12.0

5.0 - 12.0

5.0 - 12.0

Nozzle force Nozzle height (min-max)

4

700

inches

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

24.0

US gal

106

106

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

30

30

40

3+Nozzle

4+Nozzle

7.2

9.1

9

10

11

135 x 106 x 121 32000

174 x 106 x 121 33000

174 x 106 x 121 33000

44

163

163

24.0

24.0

24.0

24.8

24.8

24.8

24.8

31.4 106

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage

kw

4+Nozzle 10.7

11.7

13.1

10.7

11.7

13.1

15.9

GENERAL Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

gpm inches lbs lbs

ERC33, ERV31, ERSE31

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

51

MAINTENANCE: MACHINE SPECIFICATIONS VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES200VHRB

CLAMP Clamp force

US tons

200

Clamp opening force

US tons

14

Clamp stroke (max)

inches

15.75

Mold height (min - max)

inches

15.75

7

Daylight (min - max)

inches

15.75

7

Platen size (H x V)

inches

31.89 x 17.72

Rotary Table Diameter

inches

46.46

Mold pitch circle diameter

inches

25.59

Hydraulic ejector stroke

inches

6.3

Ejector penetration (above table)

inches

3.1

US tons

1.8

-N/A -31.50

ROTARY TABLE

Hydraulic ejector force INJECTION Screw diameter

mm

Screw diameter

inches

Shot size

1+2

Injection capacity Recovery rate

1+2

Plasticizing capacity

1+2

Injection rate at max. press.

3+4

Injection rate (regenerative)

3+4

Injection velocity at max. press. 3+4 Injection velocity (regenerative)

3+4

Screw Stroke Injection pressure (max)

4

Injection pressure (regenerative) Screw speed max (min = 25) Screw torque

4

4

330

330

330

330

600

600

600

600

700

700

700

700

30

35

40

45

40

45

50

55

45

50

55

60 2.362

1.181

1.378

1.575

1.772

1.575

1.772

1.969

2.165

1.772

1.969

2.165

oz

3.7

5.0

6.5

8.3

8.2

10.3

12.7

15.4

10.3

12.7

15.4

18.3

in3

6.9

9.4

12.3

15.5

15.3

19.4

24.0

29.0

19.4

24.0

29.0

34.5

oz/sec

0.5

0.8

0.9

1.2

0.8

1.1

1.5

1.9

0.9

1.2

1.6

2.0

lbs/hr

118

183

200

265

186

246

334

435

197

268

349

441

in3/sec

5.0

6.8

8.9

11.3

6.4

8.2

10.1

10.9

9.2

11.4

13.8

13.7

in3/sec

6.8

9.3

12.1

15.3

8.7

11.1

13.7

14.2

12.0

14.8

17.9

17.0

in/sec

4.6

4.6

4.6

4.6

3.3

3.3

3.3

2.9

3.7

3.7

3.7

3.1

in/sec

6.2

6.2

6.2

6.2

4.5

4.5

4.5

3.8

4.9

4.9

4.9

3.9

inches

6.30

6.30

6.30

6.30

7.87

7.87

7.87

7.87

psi

30000

30000

24143

21765

30000

27164

22017

20420

5

psi

30000

23200

17763

16013

22129

20037

16240

15646

5

rpm

420

420

320

6

ft-lbs

260

260

325

6

23.3:1

20:1

17.5:1

Screw L/D ratio

7.87

7.87

7.87

7.87

30000

24708

20420

20509

5

22986

18931

15646

16498

5

320

6

297

297

297

297

238

238

238

238

325

6

514

514

514

514

813

813

813

813

31.4

31.4

31.4

15.6:1

20:1

20:1

Nozzle stroke

inches

13.0

15.8

15.8

Nozzle reach to mold centre

inches

5.0

5.0

5.0

US tons

2.8

4.0

4.0

5.0 - 12.0

5.0 - 12.0

5.0 - 12.0

Nozzle force Nozzle height (min-max)

4

inches

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

24.0

US gal

106

106

106

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

30

30

40

3+Nozzle

4+Nozzle

4+Nozzle

7.2

9.1

9

10

135 x 106 x 121

174 x 106 x 121

174 x 106 x 121

32000

33000

33000

44

163

163

24.0

24.0

24.0

24.8

24.8

24.8

24.8

31.4

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage

kw

10.7

11.7

13.1

10.7

11.7

13.1

15.9

GENERAL Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity Suitable Engel robots

gpm inches lbs lbs

11

ERC33, ERV31, ERSE31

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

52

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES300VHRB

CLAMP Clamp force

US tons

300

Clamp opening force

US tons

31

Clamp stroke (max)

inches

19.70

Mold height (min - max)

inches

11.80

7

Daylight (min - max)

inches

11.80

7

Platen size (H x V)

inches

39.40 x 25.10

Rotary Table Diameter

inches

62.00

Mold pitch circle diameter

inches

35.82

Hydraulic ejector stroke

inches

5.9

Ejector penetration (above table)

inches

3.0

US tons

4.3

-N/A -31.50

ROTARY TABLE

Hydraulic ejector force

600

600

600

600

700

700

700

700

1300

1300

1300

40

45

50

55

45

50

55

60

55

60

70

1.575

1.772

1.969

2.165

1.772

1.969

2.165

2.362

2.165

2.362

2.756

oz

8.2

10.3

12.7

15.4

10.3

12.7

15.4

18.3

20.8

24.8

33.7

in3

63.4

INJECTION Screw diameter

mm

Screw diameter

inches

Shot size

1+2

Injection capacity Recovery rate

1+2

Plasticizing capacity

1+2

Injection rate at max. press.

3+4

Injection rate (regenerative)

3+4

Injection velocity at max. press.

3+4

Injection velocity (regenerative)

3+4

Screw Stroke Injection pressure (max)

4

Injection pressure (regenerative) Screw speed max (min = 25) Screw torque

4

4

15.3

19.4

24.0

29.0

19.4

24.0

29.0

34.5

39.1

46.6

oz/sec

0.8

1.1

1.5

1.9

0.9

1.2

1.6

2.0

1.4

1.8

2.7

lbs/hr

186

246

334

435

197

268

349

441

318

402

603

in3/sec

6.4

8.2

10.1

10.9

9.2

11.4

13.8

13.7

14.5

17.3

18.0

in3/sec

8.7

11.1

13.7

14.2

12.0

14.8

17.9

17.0

16.7

19.9

20.1

in/sec

3.3

3.3

3.3

2.9

3.7

3.7

3.7

3.1

3.9

3.9

3.0

in/sec

4.5

4.5

4.5

3.8

4.9

4.9

4.9

3.9

4.5

4.5

3.4

inches

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

10.63

10.63

10.63

psi

30000

27164

22017

20420

5

30000

24708

20420

20509

5

28300

23780

22774

5

psi

22129

20037

16240

15646

5

22986

18931

15646

16498

5

24542

20622

20454

5

rpm

297

297

297

297

238

238

238

238

217

217

217

ft-lbs

514

514

514

514

813

813

813

813

1305

1305

1305

46.0

46.0

Screw L/D ratio

20:1

20:1

20:1

Nozzle stroke

inches

15.8

15.8

17.7

Nozzle reach to mold centre

inches

5.0

5.0

8.5

US tons

4.0

4.0

6.6

6.75 - 16.5

6.75 - 16.5

7.5 - 14.5

Nozzle force Nozzle height (min-max)

4

inches

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

24.8

US gal

158

24.8

24.8

24.8

31.4

31.4

31.4

31.4

158

46.0 158

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

60

60

60

4+Nozzle

4+Nozzle

4+Nozzle

kw

9.1

gpm

10

11

14

260 x 109 x 145

260 x 109 x 145

260 x 109 x 145

10.7

11.7

13.1

10.7

11.7

13.1

15.9

14.7

15.9

19.1

GENERAL Water requirements (max) Machine dimensions (LxWxH)

inches

Machine weight

lbs

42000

42000

47000

Hopper capacity

lbs

163

163

163

Suitable Engel robots

ERC43, ERV41, ERSE31

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

53

MAINTENANCE: MACHINE SPECIFICATIONS

2.4

VERTICAL CLAMP, VERTICAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES60VV

ES90VV

Clamp force

US tons

60

90

Clamp opening force

US tons

3.0

3.0

CLAMP

Clamp stroke (max)

inches

13.78

13.78

Mold height (min - max)

inches

7.48 - N/A

7.48 - N/A

Daylight (min - max)

inches

7.48 - 21.26

7.48 - 21.26

27.5 x 17.7

27.5 x 17.7

38.4 5.00

46.46 6.30

Platen size (H x V) (Moving) ROTARY TABLE Rotary Table Diameter Hydraulic ejector stroke

inches inches

Hydraulic ejector force

tons

INJECTION Screw diameter

mm

Screw diameter Shot size 1+3

inches oz

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

Injection rate (regenerative)4

1.3

1.8

200

200

200

330

330

330

330

25

30

35

30

35

40

45

0.984

1.181

1.378

1.181

1.378

1.575

1.772

2.2

3.2

4.4

3.7

5.0

6.5

8.3

in3

4.2

6.0

8.2

6.9

9.4

12.3

15.5

oz/sec

0.4

0.6

0.9

0.5

0.8

0.9

1.2

lbs/hr

88

135

209

118

183

200

265

in3/sec

3.9

5.6

7.7

5.0

6.8

8.9

11.3

in3/sec

5.9

8.6

11.6

6.8

9.3

12.1

15.3

in/sec

5.1

5.1

5.1

4.6

4.6

4.6

4.6

Injection velocity (regenerative)4

in/sec

7.8

7.8

7.8

6.2

6.2

6.2

6.2

Screw Stroke

inches

5.51

5.51

5.51

6.30

6.30

6.30

6.30

psi

30000

30000

23505

30000

30000

24143

21765

psi

16013

Injection velocity at max. press.

Injection pressure (max)

4

5

Injection pressure (regenerative)5 Screw speed max (min = 25) Screw torque5

30000

21040

15456

30000

23200

17763

rpm

480

480

480

420

420

320

320

ft-lbs

163

163

163

260

260

325

325

24:1

20:1

17.1:1

23.3:1

20:1

17.5:1

15.6:1

24.0

24.0

24.0

Screw L/D ratio Nozzle stroke

inches

Nozzle force

US tons

12.99

12.99

1.7

2.8

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

16.1

US gal

106

16.1

16.1

24.0 106

ELECTRICS Power supply available

volts

230/460/575/ - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

Total rated horsepower

HP

30

30

3+Nozzle

3+Nozzle

kw

4.8

7.2

6

6

44

44

Number of heat control zones Total heating wattage GENERAL Water requirements (max)

gpm

Machine dimensions (LxWxH) Machine weight Hopper capacity

inches lbs lbs

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

54

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS VERTICAL CLAMP, VERTICAL INJECTION UNIT, ROTARY TABLE, MOLDING MACHINES

ES125VV

ES150VV

Clamp force

US tons

125

150

Clamp opening force

US tons

CLAMP

6.8

8.2

Clamp stroke (max)

inches

17.72

17.72

Mold height (min - max)

inches

7.48 - N/A

7.48 - N/A

Daylight (min - max)

inches

7.48 - 25.20

7.48 - 25.20

31.5 x 21.65

31.5 x 21.65

62.0 5.90

62.0 5.90

Platen size (H x V) (Moving) ROTARY TABLE Rotary Table Diameter Hydraulic ejector stroke

inches inches

Hydraulic ejector force

tons

INJECTION Screw diameter

mm

Screw diameter 1+3 Shot size

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

4.3

4.3

330

330

330

330

330

330

330

30

35

40

45

30

35

40

330 45

1.181

1.378

1.575

1.772

1.181

1.378

1.575

1.772 8.3

oz

3.7

5.0

6.5

8.3

3.7

5.0

6.5

in3

6.9

9.4

12.3

15.5

6.9

9.4

12.3

15.5

oz/sec

0.5

0.8

0.9

1.2

0.5

0.8

0.9

1.2

lbs/hr

118

183

200

265

118

183

200

265

in3/sec

5.0

6.8

8.9

11.3

5.0

6.8

8.9

11.3

in3/sec

6.8

9.3

12.1

15.3

6.8

9.3

12.1

15.3

in/sec

4.6

4.6

4.6

4.6

4.6

4.6

4.6

4.6

Injection velocity (regenerative)

in/sec

6.2

6.2

6.2

6.2

6.2

6.2

6.2

6.2

Screw Stroke

inches

6.30

6.30

6.30

6.30

6.30

6.30

6.30

6.30

psi

30000

30000

24143

21765

30000

30000

24143

21765

psi

Injection rate at max. press.

4

Injection rate (regenerative)4 Injection velocity at max. press.

4

4

Injection pressure (max)

5

Injection pressure (regenerative)5 Screw speed max (min = 25) 5 Screw torque

30000

23200

17763

16013

30000

23200

17763

16013

rpm

420

420

320

320

420

420

320

320

ft-lbs

260

260

325

325

260

260

325

325

23.3:1

20:1

17.5:1

15.6:1

23.3:1

20:1

17.5:1

15.6:1

24.0

24.0

24.0

Screw L/D ratio Nozzle stroke Nozzle force

inches US tons

12.99

12.99

2.8

2.8

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

24.0

US gal

106

24.0

24.0

24.0

106

24.0

230/460/575 - 3Ph/60Hz

230/460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

Number of heat control zones Total heating wattage

kw

30

30

3+Nozzle

3+Nozzle

7.2

7.2

6

6

44

44

GENERAL Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

gpm inches lbs lbs

1.Based on polystyrene material. 2. Calculated. 3. Can be increased with accumulator. 4. Can be increased. 5. Per Euromap 6 standard. 6. With high torque screw drive. 7. Split base - two piece shipping. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

55

MAINTENANCE: MACHINE SPECIFICATIONS

2.5

VERTICAL CLAMP, HORIZONTAL INJECTION UNIT, ROTARY TABLE ELASTOMER MACHINES

CLAMP Clamp force Clamping Speed (max) Opening Force Opening Stroke

US tons in/sec US tons inches

ES85VHRB

ES200VHRB

ES300VHRB

85

200

300

10.9

14.0

15.0

4.0

14.0

31.0

11.81

15.75

19.70

Mold Height (min)

inches

11.02 - 22.83

15.75 - 31.50

11.80 - 31.50

Daylight between heating platens

inches

11.02 - 22.83

15.75 - 31.50

11.80 - 31.50

Platen size (std)

inches

21.65x13.23

31.89x17.72

39.40x24.40

2x5.1/2

2x6.0/6

2x6.0/6

Heating Platen capacity/zones

kW

ROTARY TABLE Rotary Table Diameter

inches

38.39

46.46

62.00

Hydraulic ejector stroke

inches

5.00

6.30

5.90

Hydraulic ejector force

tons

INJECTION 3

Shot volume @ 29,000 PSI (max)

in

Shot volume @ 21,750 PSI (max)

in

Screw Diameter Screw

3

inches

1.3

1.8

4.3

280

430

750

430

750

1500

750

1500

2700

17.08

26.23

45.75

26.23

45.75

91.50

45.75

91.50

164.70

N/A

34.78

61.02

34.78

61.02

122.05

61.02

122.05

219.68

0.79

0.98

1.18

0.98

1.18

1.57

1.18

1.57

1.97

L/D

14:1

10:1

10:1

10:1

10:1

10:1

10:1

10:1

10:1

Injection stroke

inches

6.10

6.65

7.68

6.65

7.68

10.16

7.68

10.16

12.05

Injection rate (max)

in3/sec

7.32

Injection pressure (max) Screw speed (max) Plasticizing rate (max)

3.66

5.18

5.18

5.18

5.18

5.12

5.18

5.12

29000

29000

29000

29000

29000

29000

29000

29000

29000

rpm

250

250

200

250

200

150

200

150

160 152.0

psi in3/min

15.2

27.5

42.7

27.5

42.7

91.5

42.7

91.5

Screw torque (max)

ft-lbs

148

236

295

236

295

620

295

620

922

Strip intake opening

inches

1.6x0.5

2.0x0.5

2.4x0.6

2.0x0.5

2.4x0.6

3.2x0.7

2.4x0.6

3.2x0.7

3.5x0.8

GENERAL Pump drive motor

hp

30

40

60

Hydraulic system pressure

psi

3625

3625

3625

106 44

106 96

159 133

26432

33040

42000

124x88x107

168x106x121

192x109x145

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

kw lbs

NOTES: 1. Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

56

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS

2.6

HORIZONTAL ELASTOMER MACHINES

ES45VT

ES90VT

ES30VHL PRO

45

90

30

in/sec

--

--

38

US tons

--

--

2 13

CLAMP Clamp force

US tons

Clamping Speed (max) Opening Force Opening Stroke

inches

15.75

15.75

Mold Height (min)

inches

1.97

2.36

1.97

Daylight between heating platens

inches

18

18

15

Platen size (std)

inches

Heating Platen capacity/zones

kW

INJECTION Shot volume @ 29,000 PSI (max)

in3

Shot volume @ 21,750 PSI (max)

in

Screw Diameter Screw

3

12.60x15.75

14.17 x 19.68

11.81 x 11.81

2x6 / 2

2x6 / 2

2x2.6 / 2

160

280

160

280

200/30

200/35

9.76

17.08

9.76

17.08

6.04

--

N/A

N/A

N/A

N/A

--

8.24

inches

0.79

0.79

0.79

0.79

1.18

1.38

L/D

12:1

12:1

12:1

12:1

16:1

14:1

Injection stroke

inches

4.57

6.10

4.57

6.10

--

--

Injection rate (max)

in3/sec

3.66

3.66

4.88

4.88

4.88

6.10

29000

29000

29000

29000

30450

23200

280

280

280

250

250

250

15.26

15.26

15.26

15.26

24.4

22.5

148

148

148

148

280

280

1.4 x 0.5

1.4 x 0.5

1.4 x 0.5

1.4 x 0.5

1.2 x 2

1.2 x 2

Injection pressure (max)

psi

Screw speed (max)

rpm

Plasticizing rate (max)

in3/min

Screw torque (max)

ft-lbs

Strip intake opening

inches

GENERAL Pump drive motor

hp

15

20

15

Hydraulic system pressure

psi

3625

3625

3625

kw

34 27

53 32

24 20

lbs

--

--

6050

69X47X114

86x55x122

60x51x112

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

57

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

ES30VHL PRO

ES50VHL PRO

US tons

30

50

in/sec

38

42

CLAMP Clamp force Clamping Speed (max) Opening Force

US tons

2

3

inches

13

13.8

Mold Height (min)

inches

1.97

7.09

Daylight between heating platens

inches

15

21

Platen size (std)

inches

11.81 x 11.81

12.6 x 15.75

Opening Stroke

Heating Platen capacity/zones

kW

INJECTION

2x6 / 2

200/30

200/35

200/30

200/35

6.04

--

6.04

--

--

8.24

--

8.24

inches

1.18

1.38

1.18

1.38

L/D

17:1

Shot volume @ 29,000 PSI (max)

in3

Shot volume @ 21,750 PSI (max)

in

Screw Diameter

2x2.6 / 2

3

16:1

14:1

20:1

Injection stroke

inches

--

--

--

--

Injection rate (max)

in3/sec

4.88

6.10

4.70

6.40

Screw

30450

23200

31175

22910

rpm

250

250

480

480

in3/min

24.4

22.5

51.3

69.6

Screw torque (max)

ft-lbs

280

280

280

280

Strip intake opening

inches

1.2 x 2

1.2 x 2

2x0.8

2x0.8

Injection pressure (max)

psi

Screw speed (max) Plasticizing rate (max)

GENERAL Pump drive motor

hp

15

15

Hydraulic system pressure

psi

3625

3625

kw

24 20

30 27

lbs

6050

--

60x51x112

--

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

58

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

ES90VHL PRO

ES100V / ES100V VIC

US tons

90

100

in/sec

38

18

4

7

CLAMP Clamp force Clamping Speed (max) Opening Force

US tons

Opening Stroke

inches

17.7

18

Mold Height (min)

inches

7.87

4

Daylight between heating platens

inches

26

22

Platen size (std)

inches

14.17 x 25.98

14.17 x 19.68

Heating Platen capacity/zones

kW

INJECTION

2x6 / 6

330/35

330/40

280

430

9.40

--

17.08

26.23

45.75

--

12.27

N/A

34.78

61.02

inches

1.38

1.57

0.79

0.98

1.18

L/D

20.0

17.5

14:1

10:1

10:1

Shot volume @ 29,000 PSI (max)

in3

Shot volume @ 21,750 PSI (max)

in

Screw Diameter

2x6 / 6

3

Screw

750

Injection stroke

inches

--

--

6.10

6.65

7.68

Injection rate (max)

in3/sec

1.34

1.56

3.66

5.12

5.12

29000

22185

29000

29000

29000

rpm

400

320

280

250

200

in3/min

80.6

91.5

12.2

24.4

48.8

Screw torque (max)

ft-lbs

280

390

148

236

295

Strip intake opening

inches

2x1.2

2.4x1.2

1.6x0.5

2.0x0.5

2.4x0.6

Injection pressure (max)

psi

Screw speed (max) Plasticizing rate (max)

GENERAL Pump drive motor

hp

20

20

Hydraulic system pressure

psi

3625

3625

kw

37 32

42 27

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

lbs

--

13200

Dimensions (LxWxH)

inches

--

100 x 48 x 107

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

59

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

CLAMP Clamp force

US tons

Clamping Speed (max)

ES175V / ES175V VIC

ES275V / ES275V VIC

175

275

in/sec

22

22

US tons

12

19

Opening Stroke

inches

20

22

Mold Height (min)

inches

4

4

Daylight between heating platens

inches

24

26

Platen size (std)

inches

19.68 x 21.65

21.65 x 25.59

Opening Force

Heating Platen capacity/zones

kW

INJECTION Shot volume @ 29,000 PSI (max)

in3

Shot volume @ 21,750 PSI (max)

in

3

2x8.8 / 8

2x11 / 8

430

750

1500

750

1500

2700

26.23

45.75

91.50

45.75

91.50

164.70

34.78

61.02

122.05

61.02

122.05

219.68

inches

0.98

1.18

1.57

1.18

1.57

1.97

L/D

10:1

10:1

10:1

10:1

10:1

10:1

Injection stroke

inches

6.65

7.68

10.16

7.68

10.16

12.05

Injection rate (max)

in3/sec

5.12

5.12

5.12

7.32

7.32

7.32

29000

29000

29000

29000

29000

29000 160

Screw Diameter Screw

Injection pressure (max)

psi

Screw speed (max)

rpm

250

200

150

200

150

in3/min

24.4

48.8

91.5

48.8

91.5

152.0

Screw torque (max)

ft-lbs

236

295

620

295

620

922

Strip intake opening

inches

2.0x0.5

2.4x0.6

3.2x0.7

2.4x0.6

3.2x0.7

3.5x0.8

Plasticizing rate (max)

GENERAL Pump drive motor

hp

20

30

Hydraulic system pressure

psi

3625

3625

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

kw

42 32.6

59 44.4

lbs

15180

19580

Dimensions (LxWxH)

inches

106 x 48 x 119

101 x 55 x 126

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

60

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

CLAMP Clamp force

US tons

ES440V / ES440V VIC

ES660V

440

660

in/sec

18

18

US tons

28

28

Opening Stroke

inches

26

26

Mold Height (min)

inches

8

8

Daylight between heating platens

inches

33

33

Platen size (std)

inches

27.95 x 36.22

31.50 x 43.31

Clamping Speed (max) Opening Force

Heating Platen capacity/zones

kW

2x18 / 8

2x20 / 10

1500

2700

4500

2700

4500

91.50

164.70

274.50

164.70

274.50

488.00

122.05

219.68

366.14

219.68

366.14

640.75

inches

1.57

1.97

2.36

1.97

2.36

2.95

L/D

10:1

10:1

10:1

10:1

10:1

10:1

Injection stroke

inches

10.16

12.05

15.16

12.05

15.16

20.47

Injection rate (max)

in3/sec

14.64

14.64

14.64

14.64

14.64

14.64

psi

29000

29000

29000

29000

29000

29000

rpm

150

160

160

160

160

140

in3/min

91.5

122.0

183.0

152.0

183.0

216.5

Screw torque (max)

ft-lbs

620

922

1342

922

1342

1475

Strip intake opening

inches

3.2x0.7

3.5x0.8

3.9x0.9

3.5x0.8

3.9x0.9

4.7x1.0

INJECTION Shot volume @ 29,000 PSI (max)

in3

Shot volume @ 21,750 PSI (max)

in

Screw Diameter Screw

Injection pressure (max) Screw speed (max) Plasticizing rate (max)

3

8000

GENERAL Pump drive motor

hp

60

60

Hydraulic system pressure

psi

3625

3625

kw

108 80

113 85

lbs

44000

53900

143 x 56 x 155

152 x 59 x 186

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

61

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

CLAMP Clamp force

US tons

ES880V

ES1100V

ES60H TL

880

1100

60

in/sec

10

--

24.0

US tons

28

--

3.0

Opening Stroke

inches

35

--

13.00

Mold Height (min)

inches

12

--

7.48

Daylight between heating platens

inches

49

--

Platen size (std)

inches

35.43 x 47.24

--

12.60x15.75x2.75

2x25 / 12

--

2x5.1/2

Clamping Speed (max) Opening Force

Heating Platen capacity/zones

kW

4500

8000

8000

280

274.50

488.00

488.00

17.08

366.14

640.75

640.75

N/A

inches

2.36

2.95

2.95

0.79

L/D

10:1

10:1

10:1

14:1

Injection stroke

inches

15.16

20.55

20.55

6.10

Injection rate (max)

in3/sec

18.31

18.31

--

3.66

psi

29000

29000

29000

29000

160

140

140

250

in3/min

183.0

213.5

213.5

15.2

Screw torque (max)

ft-lbs

1342

1475

1475

148

Strip intake opening

inches

3.9x0.9

4.7x1.0

4.7x1.0

1.6x0.5

INJECTION 3

Shot volume @ 29,000 PSI (max)

in

Shot volume @ 21,750 PSI (max)

in

Screw Diameter

3

Screw

Injection pressure (max) Screw speed (max)

rpm

Plasticizing rate (max)

GENERAL Pump drive motor

hp

60

--

20

Hydraulic system pressure

psi

3625

--

3625

---

57

kw

153 104

lbs

101200

--

9600

181x69x260

--

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

62

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

ES100H TL

ES150H TL

US tons

100

150

in/sec

27.5

21.9

CLAMP Clamp force Clamping Speed (max) Opening Force

US tons

4.0

9.8

inches

17.72

23.62

Mold Height (min)

inches

9.84

9.84

Daylight between heating platens

inches

Platen size (std)

inches

14.17x19.68x2.75

17.32x19.68x2.75

2x6.0/6

2x6.0/6

Opening Stroke

Heating Platen capacity/zones

kW

INJECTION 3

Shot volume @ 29,000 PSI (max)

in

Shot volume @ 21,750 PSI (max)

in

Screw Diameter

3

inches

280

430

280

430

750

17.08

26.23

17.08

26.23

45.75

N/A

34.78

N/A

34.78

61.02

0.79

0.98

0.79

0.98

1.18

L/D

14:1

10:1

14:1

10:1

10:1

Injection stroke

inches

6.10

6.65

6.10

6.65

7.68

Injection rate (max)

in3/sec

3.66

5.18

3.66

5.18

5.18

29000

29000

29000

29000

29000

rpm

250

250

250

250

200

in3/min

15.2

27.5

15.2

27.5

42.7

Screw torque (max)

ft-lbs

148

236

148

236

295

Strip intake opening

inches

1.6x0.5

2.0x0.5

1.6x0.5

2.0x0.5

2.4x0.6

Screw

Injection pressure (max)

psi

Screw speed (max) Plasticizing rate (max)

GENERAL Pump drive motor

hp

20

30

Hydraulic system pressure

psi

3625

3625

60

116

14000

19850

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

kw lbs

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

63

MAINTENANCE: MACHINE SPECIFICATIONS HORIZONTAL ELASTOMER MACHINES

ES200H TL

ES300H TL

US tons

200

300

in/sec

23.3

CLAMP Clamp force Clamping Speed (max)

9.8

17.8

inches

27.56

33.50

Mold Height (min)

inches

9.84

13.78

Daylight between heating platens

inches

Platen size (std)

inches

19.68x21.65x3.15

21.65x25.59x3.15

Opening Force

US tons

Opening Stroke

Heating Platen capacity/zones

kW

INJECTION 3

Shot volume @ 29,000 PSI (max)

in

Shot volume @ 21,750 PSI (max)

in

3

2x8.8/8

2x11.2/8

430

750

1500

750

1500

2700

26.23

45.75

91.50

45.75

91.50

164.70

34.78

61.02

122.05

61.02

122.05

219.68

inches

0.98

1.18

1.57

1.18

1.57

1.97

L/D

10:1

10:1

10:1

10:1

10:1

10:1

Injection stroke

inches

6.65

7.68

10.16

7.68

10.16

12.05

Injection rate (max)

in3/sec

5.18

5.18

5.12

5.18

5.12

7.32

29000

29000

29000

29000

29000

29000

Screw Diameter Screw

Injection pressure (max)

psi rpm

250

200

150

200

150

160

in3/min

27.5

42.7

91.5

42.7

91.5

152.0

Screw torque (max)

ft-lbs

236

295

620

295

620

922

Strip intake opening

inches

2.0x0.5

2.4x0.6

3.2x0.7

2.4x0.6

3.2x0.7

3.5x0.8

Screw speed (max) Plasticizing rate (max)

GENERAL Pump drive motor

hp

40

50

Hydraulic system pressure

psi

3625

3625

Oil reservoir capacity Total connected load (excl.temp. control units,extra heaters,etc.) Machine weight - total (no oil)

US gal

Dimensions (LxWxH)

inches

116

kw lbs

25350

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

64

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS

2.7

DUO PLATEN INJECTION MOLDING MACHINES

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

65

MAINTENANCE: MACHINE SPECIFICATIONS DUO PLATEN INJECTION MOLDING MACHINES

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

66

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS DUO PLATEN INJECTION MOLDING MACHINES

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

67

MAINTENANCE: MACHINE SPECIFICATIONS DUO PLATEN INJECTION MOLDING MACHINES

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

68

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS

2.8

LARGE TOGGLE INJECTION MOLDING MACHINES

ES 600

CLAMP Clamp force

US tons

Clamp opening force

US tons

600 66

Clamp stroke (max)

inches

Mold height (min - max)

inches

12.2 - 31.5

Daylight (min - max)

inches

12.2 - 64.96

Platen size (H x V)

33.46

Standard - inches A

53 X 50.4

Extended - inches B

N/A

Distance between

Standard - inches A

36.02 X 33.86

tie bars (HxV)

Extended - inches B

N/A

Tie bar diameter

inches

6.10

Hydraulic ejector stroke

inches

9.84

Hydraulic ejector force

tons

10.7

INJECTION 70

3550 80

90

80

4550 90

105

3.149

3.543

3.149

3.543

4.134

Screw diameter

mm

Screw diameter Shot size 1+3

inches

2.756

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

oz

48.7

63.6

80.5

63.6

80.5

109.6

in3

91.6

119.6

151.4

119.6

151.4

206.0

oz/sec

1.3

1.8

2.6

1.8

2.5

3.5

lbs/hr

294

413

587

397

556

794

in3/sec

17.3

22.6

28.6

23.4

29.6

40.3

in3/sec

20.3

26.5

33.5

26.5

33.5

45.6

in/sec

2.9

3.0

Injection velocity (regenerative)

in/sec

3.4

3.4

Screw Stroke 5 Injection pressure (max)

inches

15.35

15.35

psi

33105

25346

20026

33350

26351

19360

psi

28205

21594

17062

29265

23123

16988

rpm

5 - 150

5 - 140

ft-lbs

2949

4718

5

Injection pressure (regenerative) Screw speed max (min = 25) 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force

20:1

20:1

inches

23.62

27.55

US tons

14.7

14.7

HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

57

91

US gal

200

243

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

100

125

kw

5+NOZZLE 33.6

5 + NOZZLE 33.6 38.8 45.6

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH)

30.6

38.8

sec

3.9

gpm

22

22

360x95x105

385x95x105

inches

4.3

Machine weight

lbs

63000

66000

Hopper capacity

lbs

300

300

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

69

MAINTENANCE: MACHINE SPECIFICATIONS LARGE TOGGLE INJECTION MOLDING MACHINES

ES750

CLAMP Clamp force

US tons

Clamp opening force

US tons

750 86

Clamp stroke (max)

inches

35.43

Mold height (min - max)

inches

15.75 - 36.22

Daylight (min - max)

inches

Platen size (H x V)

15.75 - 71.65

Standard - inches A

59.06 X 54.72

Extended - inches B

N/A

Distance between

Standard - inches A

40.35 X 36.42

tie bars (HxV)

Extended - inches B

N/A

Tie bar diameter

inches

6.69

Hydraulic ejector stroke

inches

10.82

Hydraulic ejector force

tons

16.8

INJECTION Screw diameter

mm

Screw diameter Shot size 1+3

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

80

4550 90

105

90

7050 105

120

3.149

3.543

4.134

3.543

4.134

4.724

oz

63.6

80.5

109.6

99.1

134.9

176.2

in3

119.6

151.4

206.0

186.4

253.7

331.3

oz/sec

1.8

2.5

3.5

2.3

3.2

4.7

lbs/hr

397

556

794

508

730

1048

in3/sec

23.4

29.6

40.3

28.6

38.9

50.8

in3/sec

26.5

33.5

45.6

35.5

48.3

63.1

in/sec

3.0

2.9

Injection velocity (regenerative)

in/sec

3.4

3.6

Screw Stroke 5 Injection pressure (max)

inches

15.35

18.90

psi

33350

26351

19360

33223

30346

23234

psi

29265

23123

16988

32609

23958

18343

rpm

5 - 140

5 - 130

ft-lbs

4718

7375

5

Injection pressure (regenerative) Screw speed max (min = 25) 5 Screw torque

20:1

20:1

inches

27.55

37.40

US tons

14.7

15.9

Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

91

118

US gal

266

405

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

125

150

kw

5 + NOZZLE 33.6 38.8 45.6

5 + NOZZLE 38.6 45.6 53.6

sec

4.3

4.7

gpm

22

34

411x111x112

435x128x112

80000

71000 / 46000

300

300

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

inches lbs lbs

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

70

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS LARGE TOGGLE INJECTION MOLDING MACHINES

ES 800

CLAMP Clamp force

US tons

Clamp opening force

US tons

Clamp stroke (max)

800 86

inches

35.43

Mold height (min - max)

inches

15.75 - 40.16

Daylight (min - max)

inches

Platen size (H x V)

15.75 - 75.59

Standard - inches A

64.30 X 66.73

Extended - inches B

N/A

Distance between

Standard - inches A

45.00 X 45.00

tie bars (HxV)

Extended - inches B

N/A

Tie bar diameter

inches

7.09

Hydraulic ejector stroke

inches

9.84

Hydraulic ejector force

tons

12.4

INJECTION Screw diameter

mm

Screw diameter Shot size 1+3

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

80

4550 90

105

90

7050 105

120

3.149

3.543

4.134

3.543

4.134

4.724

oz

63.6

80.5

109.6

99.1

134.9

176.2

in3

119.6

151.4

206.0

186.4

253.7

331.3

oz/sec

1.8

2.5

3.5

2.3

3.2

4.7

lbs/hr

397

556

794

508

730

1048

in3/sec

23.4

29.6

40.3

28.6

38.9

50.8

in3/sec

26.5

33.5

45.6

35.5

48.3

63.1

in/sec

3.0

2.9

Injection velocity (regenerative)

in/sec

3.4

3.6

Screw Stroke 5 Injection pressure (max)

inches

15.35

18.90

psi

33350

26351

19360

33223

30346

23234

psi

29265

23123

16988

32609

23958

18343

rpm

5 - 140

5 - 130

ft-lbs

4718

7375

5

Injection pressure (regenerative) Screw speed max (min = 25) 5 Screw torque

20:1

20:1

inches

27.55

37.40

US tons

14.7

15.9

Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity (required)

gpm

Oil reservoir capacity

US gal

91

118

266

405

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

125

150

kw

5 + NOZZLE 33.6 38.8 45.6

5 + NOZZLE 38.6 45.6 53.6

sec

4.7

4.7

gpm

22

34

inches

475x106x118

475x128x102

lbs

87000 / 40000

87000 / 46000

300

300

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

lbs

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

71

MAINTENANCE: MACHINE SPECIFICATIONS LARGE TOGGLE INJECTION MOLDING MACHINES

ES 1000

CLAMP Clamp force

US tons

Clamp opening force

US tons

1000 106

Clamp stroke (max)

inches

39.37

Mold height (min - max)

inches

15.75 - 39.37

Daylight (min - max)

inches

15.75 - 78.74

Platen size (H x V)

Standard - inches A

66 x 61

Extended - inches B

N/A

Distance between

Standard - inches A

44.09 X 40.35

tie bars (HxV)

Extended - inches B

N/A

Tie bar diameter

inches

7.87

Hydraulic ejector stroke

inches

11.81

Hydraulic ejector force

tons

26.2

INJECTION Screw diameter

mm

Screw diameter Shot size 1+3

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

90

7050 105

120

105

11050 120

135

3.543

4.134

4.724

4.134

4.724

5.315

oz

99.1

134.9

176.2

160.2

209.2

264.8

in3

186.4

253.7

331.3

301.2

393.4

497.9

oz/sec

2.3

3.2

4.7

3.0

4.3

5.8

lbs/hr

508

730

1048

675

968

1317

in3/sec

28.6

38.9

50.8

33.6

43.8

55.5

in3/sec

35.5

48.3

63.1

47.0

61.4

77.7

in/sec

2.9

2.5

Injection velocity (regenerative)

in/sec

3.6

3.5

Screw Stroke 5 Injection pressure (max)

inches

18.90

22.44

psi

33223

30346

23234

33289

28422

22457

psi

32609

23958

18343

27103

20751

16396

rpm

5 - 130

5 - 120

ft-lbs

7375

7375

5

Injection pressure (regenerative) Screw speed max (min = 25) 5 Screw torque

20:1

20:1

inches

37.40

43.31

US tons

15.9

15.9

Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

118

133

US gal

405

405

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

150

175

kw

5 + NOZZLE 38.6 45.6 53.6

5 + NOZZLE 45.8 53.8 62.4

sec

4.7

4.7

gpm

34

34

468x110x100

480x110x100

99000 / 46000

99000 / 50000

300

300

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

inches lbs lbs

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

72

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS LARGE TOGGLE INJECTION MOLDING MACHINES

ES 1000W

CLAMP Clamp force

US tons

Clamp opening force

US tons

1000 106

Clamp stroke (max)

inches

39.37

Mold height (min - max)

inches

15.75 - 39.37

Daylight (min - max)

inches

15.75 - 78.74

Platen size (H x V)

Standard - inches A Extended - inches B

N/A

Distance between

Standard - inches A

60.00 x 45.28

tie bars (HxV)

Extended - inches B

83.23 x 71.85

N/A

Tie bar diameter

inches

8.66

Hydraulic ejector stroke

inches

11.81

Hydraulic ejector force

tons

26.2

INJECTION Screw diameter

mm

Screw diameter Shot size 1+3

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

90

7050 105

120

105

11050 120

135

3.543

4.134

4.724

4.134

4.724

5.315

oz

99.1

134.9

176.2

160.2

209.2

264.8

in3

186.4

253.7

331.3

301.2

393.4

497.9

oz/sec

2.3

3.2

4.7

3.0

4.3

5.8

lbs/hr

508

730

1048

675

968

1317

in3/sec

28.6

38.9

50.8

33.6

43.8

55.5

in3/sec

35.5

48.3

63.1

47.0

61.4

77.7

in/sec

2.9

2.5

Injection velocity (regenerative)

in/sec

3.6

3.5

Screw Stroke 5 Injection pressure (max)

inches

18.90

22.44

psi

33223

30346

23234

33289

28422

22457

psi

32609

23958

18343

27103

20751

16396

rpm

5 - 130

5 - 120

ft-lbs

7375

7375

5

Injection pressure (regenerative) Screw speed max (min = 25) 5 Screw torque

20:1

20:1

inches

37.40

43.31

US tons

15.9

15.9

Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

118

133

US gal

405

405

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

150

175

kw

5 + NOZZLE 38.6 45.5 53.6

5 + NOZZLE 45.8 53.8 62.4

sec

4.7

4.7

gpm

34

34

513x136x115

525x136x115

134000 / 46000

134000 / 50000

300

300

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

inches lbs lbs

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

73

MAINTENANCE: MACHINE SPECIFICATIONS LARGE TOGGLE INJECTION MOLDING MACHINES

ES1300W

CLAMP Clamp force

US tons

Clamp opening force

US tons

Clamp stroke (max)

1300 106

inches

43.31

Mold height (min - max)

inches

15.75 - 47.24

Daylight (min - max)

inches

15.75 - 90.55

Platen size (H x V)

Standard - inches A Extended - inches B

N/A

Distance between

Standard - inches A

60.00 x 45.28

tie bars (HxV)

Extended - inches B

83.23 x 71.85

N/A

Tie bar diameter

inches

8.66

Hydraulic ejector stroke

inches

11.81

Hydraulic ejector force

tons

24.2

INJECTION 90

7050 105

120

105

11050 120

135

3.543

4.134

4.724

4.134

4.724

5.315

oz

99.1

134.9

176.2

160.2

209.2

264.8

in3

186.4

253.7

331.3

301.2

393.4

497.9

oz/sec

2.3

3.2

4.7

3.0

4.3

5.8

lbs/hr

508

730

1048

675

968

1317

in3/sec

28.6

38.9

50.8

33.6

43.8

55.5

in3/sec

35.5

48.3

63.1

47.0

61.4

77.7

in/sec

2.9

Screw diameter

mm

Screw diameter Shot size 1+3

inches

Injection capacity 1+2+3 Recovery rate Plasticizing capacity

1+2+3

Injection rate at max. press.

4

4

Injection rate (regenerative)

Injection velocity at max. press.

4

4

2.5

Injection velocity (regenerative)

in/sec

3.6

3.5

Screw Stroke 5 Injection pressure (max)

inches

18.90

22.44

psi

33223

30346

23234

33289

28422

22457

psi

32609

23958

18343

27103

20751

16396

rpm

5 - 130

5 - 120

ft-lbs

7375

7375

5

Injection pressure (regenerative) Screw speed max (min = 25) 5 Screw torque

20:1

20:1

inches

37.40

43.31

US tons

15.9

15.9

Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity (required) Oil reservoir capacity

gpm

166

166

US gal

405

405

460/575 - 3Ph/60Hz

460/575 - 3Ph/60Hz

ELECTRICS Power supply available

volts

Total rated horsepower

HP

225

225

kw

5 + NOZZLE 38.6 45.6 53.6

5 + NOZZLE 45.8 53.8 62.4

sec

5.7

5.7

gpm

34

34

602x136x115

614x136x115

170000 / 46000

170000 / 50000

300

300

Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

inches lbs lbs

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

74

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

75

MAINTENANCE: 2.9

PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES

CLAMP Clamp force Clamp opening force Clamp stroke (max) Mold height (min - max) Daylight (min - max) Platen size (H x V) Distance between tie bars (HxV) Tie bar diameter Hydraulic ejector stroke Hydraulic ejector force INJECTION Screw diameter Screw diameter 1+3 Shot size Injection capacity 1+2+3 Recovery rate 1+2+3 Plasticizing capacity 4 Injection rate at max. press. 4 Injection rate (regenerative) 4 Injection velocity at max. press. )4 Injection velocity (regenerative Screw stroke 5 Injection pressure (max) 5 Injection pressure (regenerative) Screw speed range 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity System pressure Oil reservoir capacity ELECTRICS Power supply available Total rated horsepower Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

US tons US tons inches inches inches Standard - inches A Extended - inches B Standard - inches A Extended - inches B inches inches tons mm inches oz 3 in oz/sec lbs/hr 3 in /sec 3 in /sec in/sec in/sec inches psi psi rpm ft-lbs inches US tons gpm psi US gal volts HP kw sec gpm inches lbs lbs

ES 100 100 10 12.20 9 9.84 - 20.87 9 9.84 - 33.07 22.68x22.68 N/A 15.98x15.98 N/A 2.36 3.94 2.8 330 30 35 40 45 1.181 1.378 1.575 1.772 3.7 5.0 6.5 8.3 6.9 9.4 12.3 15.5 0.9 1.2 0.9 1.0 203 270 203 225 5.0 6.8 8.9 9.8 6.8 9.3 12.1 15.2 4.6 4.6 4.6 4.6 6.2 6.2 6.2 6.2 6.3 30000 30000 24143 21765 30000 23200 17763 16013 25-420 25-420 25-320 25-320 260 260 325 325 23.3:1 20:1 17.5:1 15.6:1 9.84 5.2

ES 150 150 18 16.54 5.91 - 20.47 5.91 - 37.01 N/A 28.35x25.20 N/A 19.69x16.54 2.95 5.12 6.8 600 40 45 1.575 1.772 8.2 10.3 15.3 19.4 1.1 1.3 248 293 6.4 8.2 8.7 11.1 3.3 3.3 4.5 4.5 7.87 30000 27173 25361 20039 25-297 514 20:1 11.81 7.4

24.0 2654 41

24.8 2320 113

230/460/575/ - 3Ph/60Hz 20 3+Nozzle 7.2

230/460/575 - 3Ph/60Hz 30 4+Nozzle 9.1 10.7 11.7 13.1

1.7 6 165x52x80 9500 44

1.6 8 227x67x86 16200 163

50 1.969 12.7 24.0 1.9 423 10.1 13.7 3.3 4.5

55 2.165 15.4 29.0 2.3 518 10.9 14.2 3.0 3.9 7

22011 20416 7 16240 15646

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

76

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES

CLAMP Clamp force Clamp opening force Clamp stroke (max) Mold height (min - max) Daylight (min - max) Platen size (H x V) Distance between tie bars (HxV) Tie bar diameter Hydraulic ejector stroke Hydraulic ejector force INJECTION Screw diameter Screw diameter 1+3 Shot size Injection capacity 1+2+3 Recovery rate 1+2+3 Plasticizing capacity 4 Injection rate at max. press. 4 Injection rate (regenerative) 4 Injection velocity at max. press. )4 Injection velocity (regenerative Screw stroke 5 Injection pressure (max) 5 Injection pressure (regenerative) Screw speed range 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity System pressure Oil reservoir capacity ELECTRICS Power supply available Total rated horsepower Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

US tons US tons inches inches inches Standard - inches A Extended - inches B Standard - inches A Extended - inches B inches inches tons mm inches oz 3 in oz/sec lbs/hr 3 in /sec 3 in /sec in/sec in/sec inches psi psi rpm ft-lbs inches US tons gpm psi US gal volts HP kw sec gpm inches lbs lbs

ES 200 200 25 18.11 5.91 - 22.05 5.91 - 40.16 N/A 30.71x27.36 N/A 21.26x18.11 3.35 5.91 6.8 700 45 50 1.772 1.969 10.3 12.7 19.4 24.0 1.0 1.5 225 338 9.2 11.4 12.0 14.8 3.7 3.7 4.9 4.9 7.87 30000 24708 23374 18923 25-238 813 20:1 11.81 7.4

ES 250 250 33 20.08 7.87 - 24.02 7.87 - 44.09 32.68x32.68 N/A 22.44x22.44 N/A 3.54 5.91 6.8 700 55 60 45 50 2.165 2.362 1.772 1.969 15.4 18.4 10.3 12.7 29.0 34.5 19.4 24.0 1.8 2.1 1.0 1.5 405 423 225 338 13.8 13.7 9.2 11.4 17.9 17.0 12.0 14.8 3.7 3.1 3.7 3.7 4.9 3.9 4.9 4.9 7.87 7 20416 20518 30000 24708 7 15646 16500 23374 18923 25-238 813 20:1 11.81 7.4

55 2.165 15.4 29.0 1.8 404 13.8 17.9 3.7 4.9

31.4 2320 125

460/575 - 3Ph/60Hz 40 4+Nozzle 10.7 11.7 13.1

460/575 - 3Ph/60Hz 40 4+Nozzle 10.7 11.7 13.1

1.8 11 248x70x86 19000 163

7

20416 20518 7 15646 16500

31.4 2320 125

15.9

60 2.362 18.4 34.5 2.1 423 13.7 17.0 3.1 3.9

15.9

1.9 11 248X70X89 26100 163

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

77

MAINTENANCE: MACHINE SPECIFICATIONS PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES

CLAMP Clamp force Clamp opening force Clamp stroke (max) Mold height (min - max) Daylight (min - max) Platen size (H x V) Distance between tie bars (HxV) Tie bar diameter Hydraulic ejector stroke Hydraulic ejector force INJECTION Screw diameter Screw diameter 1+3 Shot size Injection capacity 1+2+3 Recovery rate 1+2+3 Plasticizing capacity 4 Injection rate at max. press. 4 Injection rate (regenerative) 4 Injection velocity at max. press. )4 Injection velocity (regenerative Screw stroke 5 Injection pressure (max) 5 Injection pressure (regenerative) Screw speed range 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity System pressure Oil reservoir capacity ELECTRICS Power supply available Total rated horsepower Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

US tons US tons inches inches inches Standard - inches A Extended - inches B Standard - inches A Extended - inches B inches inches tons mm inches oz 3 in oz/sec lbs/hr 3 in /sec 3 in /sec in/sec in/sec inches psi psi rpm ft-lbs inches US tons gpm psi US gal volts HP kw sec gpm inches lbs lbs

ES 300 300 42 23.62 7.87 - 25.98 7.87 - 49.60 35.67x35.87 N/A 25.04x25.04 N/A 3.94 7.87 8.9 1300 55 60 2.165 2.362 20.8 24.8 39.2 46.6 1.7 1.8 383 404 14.5 17.3 16.7 19.9 3.9 3.9 4.5 4.5 10.63 28304 23780 24534 20619 25-217 1305 20:1 13.78 12.1

70 2.756 33.7 63.4 2.4 540 18.0 20.0 3.0 3.4 7

22780 7 20460

ES 400 400 57 27.56 11.81 - 33.94 11.81 - 61.50 44.56x44.56 N/A 30.00x30.00 N/A 5.51 9.45 8.9 2000 60 70 2.362 2.756 28.4 38.7 53.5 72.8 1.6 2.2 360 495 16.7 22.8 19.2 26.1 3.8 3.8 4.4 4.4 12.2 30000 22577 26811 19690 25-198 1790 20:1 21.65 12.1

80 3.150 50.6 95.1 2.8 630 20.1 22.0 2.6 2.8

85 3.346 57.1 107.4 2.7 608 22.7 24.9 2.6 2.8 7

7

25549 22635 7 7 23345 20677 8 25-162 8 2186

46.0 2320 145

57.6 2320 204

460/575 - 3Ph/60Hz 50 4+Nozzle 14.7 15.9 19.1

460/575 - 3Ph/60Hz 60 4+Nozzle 18.3 21.5 24.7

2.0 14 298X72X94 34100 163

2.6 17 359x87x101 49000 163

26.1

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

78

2. GENERAL MACHINE SPECIFICATIONS

16/12/05

MAINTENANCE: MACHINE SPECIFICATIONS PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES

CLAMP Clamp force Clamp opening force Clamp stroke (max) Mold height (min - max) Daylight (min - max) Platen size (H x V) Distance between tie bars (HxV) Tie bar diameter Hydraulic ejector stroke Hydraulic ejector force INJECTION Screw diameter Screw diameter 1+3 Shot size Injection capacity 1+2+3 Recovery rate 1+2+3 Plasticizing capacity 4 Injection rate at max. press. 4 Injection rate (regenerative) 4 Injection velocity at max. press. )4 Injection velocity (regenerative Screw stroke 5 Injection pressure (max) 5 Injection pressure (regenerative) Screw speed range 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity System pressure Oil reservoir capacity ELECTRICS Power supply available Total rated horsepower Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

US tons US tons inches inches inches Standard - inches A Extended - inches B Standard - inches A Extended - inches B inches inches tons mm inches oz 3 in oz/sec lbs/hr 3 in /sec 3 in /sec in/sec in/sec inches psi psi rpm ft-lbs inches US tons gpm psi US gal volts HP kw sec gpm inches lbs lbs

ES 450 450 57 27.56 11.81 - 33.94 11.81 - 61.50 44.56x44.56 47.24x47.24 30.00x30.00 33.07x33.07 5.51 9.45 8.9 2000 60 70 2.362 2.756 28.4 38.7 53.5 72.8 1.6 2.2 360 495 16.7 22.8 19.2 26.1 3.8 3.8 4.4 4.4 12.2 30000 22577 26811 19690 25-198 1790 20:1 21.65 12.1

80 3.150 50.6 95.1 2.8 630 20.1 22.0 2.6 2.8 7

25549 7 23345

ES 500 500 60 27.56 11.81 - 33.94 11.81 - 61.50 47.80x47.24 N/A 34.65x33.07 N/A 5.51 9.45 8.9 2000 85 60 70 3.346 2.362 2.756 57.1 28.4 38.7 107.4 53.5 72.8 2.7 1.6 2.2 608 360 495 22.7 16.7 22.8 24.9 19.2 26.1 2.6 3.8 3.8 2.8 4.4 4.4 12.2 7 22635 30000 22577 7 20677 26811 19690 8 25-162 25-198 8 2186 1790 20:1 21.65 12.1

80 3.150 50.6 95.1 2.8 630 20.1 22.0 2.6 2.8

2750 90 3.543 64.0 120.4 3.5 788 31.0 33.9 3.1 3.4 12.2 7 22635 22635 7 20677 20677 8 8 25-162 25-197 8 8 2186 2186 20:1 21.65 12.1

85 3.346 57.1 107.4 2.7 608 22.7 24.9 2.6 2.8 7

25549 7 23345

57.6 2320 204

57.6 2320 204

70.0 2600 204

460/575 - 3Ph/60Hz 60 4+Nozzle 18.3 21.5 24.7

460/575 - 3Ph/60Hz 60 4+Nozzle 18.3 21.5 24.7

same 75 5+Nozzle 39.3

26.1

2.6 17 359x87x101 53500 163

26.1

2.6 17 363x88x101 55200 163

2.5 21 385x88x101 57300 163

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

16/12/05

2. GENERAL MACHINE SPECIFICATIONS

79

MAINTENANCE: MACHINE SPECIFICATIONS PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES

CLAMP Clamp force Clamp opening force Clamp stroke (max) Mold height (min - max) Daylight (min - max) Platen size (H x V) Distance between tie bars (HxV) Tie bar diameter Hydraulic ejector stroke Hydraulic ejector force INJECTION Screw diameter Screw diameter 1+3 Shot size Injection capacity 1+2+3 Recovery rate 1+2+3 Plasticizing capacity 4 Injection rate at max. press. 4 Injection rate (regenerative) 4 Injection velocity at max. press. )4 Injection velocity (regenerative Screw stroke 5 Injection pressure (max) 5 Injection pressure (regenerative) Screw speed range 5 Screw torque Screw L/D ratio Nozzle stroke Nozzle force HYDRAULICS Pump Capacity System pressure Oil reservoir capacity ELECTRICS Power supply available Total rated horsepower Number of heat control zones Total heating wattage GENERAL 6 Dry cycle performance Water requirements (max) Machine dimensions (LxWxH) Machine weight Hopper capacity

US tons US tons inches inches inches Standard - inches A Extended - inches B Standard - inches A Extended - inches B inches inches tons mm inches oz 3 in oz/sec lbs/hr 3 in /sec 3 in /sec in/sec in/sec inches psi psi rpm ft-lbs inches US tons gpm psi US gal volts HP kw sec gpm inches lbs lbs

ES 500W 500 60 27.56 11.81 - 33.94 11.81 - 61.50 58.26x47.24 N/A 44.09x33.07 N/A 5.51 9.45 8.9 2000 60 70 2.362 2.756 28.4 38.7 53.5 72.8 1.6 2.2 360 495 16.7 22.8 19.2 26.1 3.8 3.8 4.4 4.4 12.2 30000 22577 26811 19690 25-198 1790 20:1 21.65 12.1

80 3.150 50.6 95.1 2.8 630 20.1 22.0 2.6 2.8

85 3.346 57.1 107.4 2.7 608 22.7 24.9 2.6 2.8 7

25549 7 23345

7

22635 7 20677 8 25-162 8 2186

2750 90 3.543 64.0 120.4 3.5 788 31.0 33.9 3.1 3.4 12.2 22635 20677 8 25-197 8 2186 20:1 21.65 12.1

57.6 2320 204

70.0 2600 204

460/575 - 3Ph/60Hz 60 4+Nozzle 18.3 21.5 24.7

same 75 5+Nozzle 39.3

26.1

2.6 17 363x100x101 75000 163

2.5 21 385x88x101 57300 163

1.Based on polystyrene material. 2. Based on HDPE material (ES600+). 3. Calculated. 4. Can be increased with accumulator. 5. Can be increased. 6. Per Euromap 6 standard. 7. With increased injection pressure . 8. With high torque screw drive. 9. Smaller mold hieght settings optional. (N/A=Not Available. O/R=On Request. Std.=Standard)

80

2. GENERAL MACHINE SPECIFICATIONS

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MAINTENANCE 3. SAFETY DEVICES 1.

MACHINE SAFETY FEATURES

NOTE! Do not operate machine unless all safety features are in place and functioning properly. These safety features are typical of an ENGEL machine but may vary with machine size and options. These protective features are built into the machine to protect personnel. The user is responsible for each protective device being in good working order before the machine is placed in operation. The user must maintain these safety features in working order. Operational and maintenance personnel must be trained to recognize that variations in machine configuration (i.e. vertical or horizontal clamp), machine size and age may result in changes to the design and position of safety features and guards. We very strongly recommend that the safety features are inspected at the beginning of each shift and when a new mold is installed. A log should be kept detailing when and by whom the inspections were performed. MAIN DISCONNECT SWITCH -

Operating the main disconnect switch to open the electrical cabinet door, disconnects electrical power downstream of that main disconnect switch. L1, L2, and L3 entering the cabinet are live unless the electrical power to the machine has been disconnected. Check that operating the main electrical disconnect switch on the machine, disconnects electrical power at the machine. EMERGENCY STOP BUTTON

-

Pushing this switch in will break the electric motor circuit causing the motor to stop. Restart of the motor should not be possible until the button is released. Check that motor stops when emergency stop button is pressed. MECHANICAL SAFETY DEVICE

-

Mechanically prevents clamp closure when operator side gate is open. Some designs require adjustment to suit various mold open strokes. Please refer to detailed directions elsewhere in this manual. Check that mechanism moves freely and is correctly adjusted. PURGE GUARD

-

Provides operator protection during purging. Activates limit switch E9 to prevent injection when the purge guard is raised. Check that a raised purge guard prevents carriage movement.

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81

MAINTENANCE -

ES 30/55 machines have a sliding guard which performs the duties of the purge guard. This guard actuates E9 limit switch.

HYDRAULIC INTERLOCK -

Cuts the flow of hydraulic fluid to the clamp cylinder thereby preventing clamp closure. Check that pushing back the hydraulic interlock arm, stops clamp closure.

BARREL HEATSHIELD -

Provides operator protection from direct contact with heater bands. Check that shields are in place before heating up the barrel.

SAFETY GATE (OPERATOR SIDE) -

Provides protection from the moving clamp. Activates mechanical safety device, hydraulic interlock, limit switches E1 and E2. Check that opening gate activates appropriate devices and prevents clamp closure.

SAFETY GATE (NON-OPERATOR SIDE) -

Provides protection from the moving clamp. Activates limit switches E3 and E4 to stop motor. Check that opening this gate causes motor to stop. ES 30/55 with a single gate may not have switches E3 and E4.

COVER AROUND CLAMP ASSEMBLY -

Provides protection from the toggle mechanism while machine is in operation. Check that panels are securely fastened in position.

E10 LIMIT SWITCH ON -

Releasing the bar, to allow the operator side gate to be opened passed the moving platen for access to the area behind the clamp, engages limit switch E10. The limit switch is in the Emergency stop circuit, when the limit switch is engaged the machine is immobilized.

E21 LIMIT SWITCH ON MOVING PLATEN DROP-BAR MECHANICAL INTERLOCK -

(This device is not installed on all machines) Check that clamp closure is prevented as soon as the bar is raised. Opening the operator safety gate will deactivate limit switch E21. Digital input 28 will go low (0 Volts). Closing the operator safety gate will actuate limit switch E21. Digital input 28 will go high (24Volts), indicating that the mechanical interlock has been released.

E52 LIMIT SWITCH INDICATING INJECTION UNIT ALIGNMENT -

82

(This switch is not installed on all machines) Rotation of the carriage, to permit barrel change, will actuate limit switch E52. On ES30/55 this switch is operated by movement of the swinging injection guard. Check that activation of E52 prevents injection.

3. SAFETY DEVICES

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MAINTENANCE SAFETY FEATURES ES 30/55

Find No. 1 2 3 4 5 6 7 8 9 Switch E1, E2, E3, E4 E9 E10 E52

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Description Main Disconnect Switch on Electrical Cabinet Emergency Stop Button Mechanical Safety Device (Closing Protection) Hydraulic Interlock Heat Shield over Barrel Safety Gates (Operator and Non-Operator Sides) Injection Guard (Sliding) Injection Guard (Swinging) Hard Covers around Clamp and Injection Units Limit Switches on Safety Gates Limit Switch on Sliding Injection Guard Limit Switch on Moving Platen Drop Bar (may not be installed) Limit Switch on Swinging Injection Guard

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83

MAINTENANCE SAFETY FEATURES ES85. 8

AS1

AS2

AS1

Find No. 1 2 3 4 5 6 7 8 Switch E1, E2, E3, E4 AS1, AS2 E9 E10 E52

84

E2

5

E1

E4

E2

4

3

E10

2

7

E1

7

E3

3

6

E9

2

1

E52

1

Description Main Disconnect Switch on Electrical Cabinet Emergency Stop Button Mechanical Safety Device (Closing Protection) Purge Guard Hydraulic Interlock Heat Shield over Barrel Safety Gates (Operator and Non-Operator Sides) Hard Covers around Clamp and Injection Units Limit Switches on Safety Gates Limit Switches on Plexi-Glass Panels Limit Switch on Sliding Injection Guard Limit Switch on Moving Platen Drop Bar (may not be installed) Limit Switch on Swinging Injection Guard

3. SAFETY DEVICES

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MAINTENANCE SAFETY FEATURES ES 100 9

E21

3 9

E21

Find No. 1 2 3 4 5 6 7 8 9 Switch E1, E2, E3, E4 E9 E52 E21

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5

E2 E4

4

4

E2

E1 E3

6

7

E1

8

2 2

2

E9 E52 9

E9

1

9

E52

Description Main Disconnect Switch on Electrical Cabinet Emergency Stop Button Mechanical Safety Device (Closing Protection) Hydraulic Interlock Heat Shield over Barrel Safety Gates (Operator and Non-Operator Sides) Injection Guard (Sliding) Injection Guard (Swinging) Hard Covers around Clamp and Injection Units Limit Switches on Safety Gates Limit Switch on Sliding Injection Guard Limit Switch on Swinging Injection Guard Limit Switch on Moving Platen Drop Bar

3. SAFETY DEVICES

85

MAINTENANCE SAFETY FEATURES (TL100 TIEBARLESS)

E21

3 E10

7

5

6

8

9 9 E9

E52 1 E4 4 E2

Legend 1 2 3 4 5 6 7 8 9 Switches E1, E2, E3, E4 E9 E10 E21 E52

86

E3 E1

2

Description Main Electrical Power Disconnect Emergency Stop button Mechanical Safety Device (Closing Protection) Hydraulic Interlock Barrel Heatshield Safety Gates (Operator and Non Operator) Injection Guard (sliding) Injection Guard (swinging) Hard Covers around Clamp and Injection unit Limit switch on Safety Gates Limit switch on sliding injection guard (Nozzle Guard) Limit switch on Operator gate stop Limit switch on Moving Platen Dropbar mechanical interlock Limit switch on swinging injection guard

3. SAFETY DEVICES

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MAINTENANCE SAFETY FEATURES ES200 TOGGLE

4 8

8

E21

E10 7

3

E9

6 E52

E2 E1 Legend 1 2 3 4 5 6 7 8 Switches E1, E2, E3, E4 E9 E10 E21 E52

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E4

E3 2

1

5

Description Main Electrical Power Disconnect Emergency Stop button Mechanical Safety Device (Closing Protection) Purge Guard Hydraulic Interlock Barrel Heatshield Safety Gates (Operator and Non Operator) Hard Covers around Clamp and Injection unit

Limit on Safety Gates Limit switch on sliding injection guard (Nozzle Guard) Limit switch on Operator safety gate stop Limit switch on Moving Platen Dropbar mechanical interlock Limit switch on swinging injection guard

3. SAFETY DEVICES

87

MAINTENANCE SAFETY FEATURES ES300 to ES500 6 E21

3

2

E8.1 E1 E2

4 5 1

2

E3 E9

E4 E8.2

2

Find No. 1 2 3 4 5 6 7 Switch E21 E1 E2 E3 E4 E8.1 E8.2 E9

88

1

3

Description Safety Gates (Operator and Non-Operator Sides) Hard Covers around Clamp Injection Guard (Sliding) Main Disconnect Switch on Electrical Cabinet Emergency Stop Button Mechanical Safety Device (Closing Protection) Hydraulic Interlock Limit Switch on Mechanical Interlock Limit Switch on Operator Side Safety Gate Limit Switch on Operator Side Safety Gate Limit Switch on Non Operator Side Safety Gate Limit Switch on Non Operator Side Safety Gate Limit Switch on Operator Side Hydraulic Interlock Limit Switch on Non Operator Side Hydraulic Interlock Limit Switch on Injection / Purge Guard

3. SAFETY DEVICES

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MAINTENANCE SAFETY FEATURES ES600 to ES3500

OPERATOR SIDE

E8

2

1

E3, E4

E55

E9

2

Find No. 1 2 3 4 5 6 Switch E10 E1 E2 E8 E8.1 E9 E3 E4 E52

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E2

E8.1

bE10

1

3

E1

Description Safety Gates (Operator and Non Operator side) Hard Covers around Clamp (Operator and Non Operator side) Purge Guard around Injection Unit Main Electrical Disconnect On Cabinet Emergency Stop Button Hydraulic Interlock Front Safety Gate Safety Gate Closed Safety Gate Not Closed Hydraulic Clamp Interlock Front Safety Gate Not Closed Purge Guard Closed Rear Safety Gate L.S. Rear Safety Gate L.S. Injection Unit aligned

3. SAFETY DEVICES

89

MAINTENANCE 2.

MECHANICAL SAFETY DEVICES

There are four types of mechanical safety devices used on ENGEL machines. Be aware of the type of mechanical safety device used on the machine and of the adjustments required (if any) to ensure maximum protection. Mechanical Safety Type 1 STRIKE PLATE SPLIT RING

GUIDE BLOCK

STOP BAR

MOVING PLATEN

STOP BLOCK

STATIONARY PLATEN

When the front safety gate and the clamp are both open, the strike plate drops covering the hole through which the stop bar passes. Thus preventing the clamp from closing. As the front safety gate closes, the strike plate is lifted uncovering the hole through which the safety bar moves when the clamp closes. In order for this protective device to operate properly, the stop bar must be adjusted as close to the strike plate as possible, with the clamp open. The stop bar has a series of cylindrical grooves into which is inserted a split ring. A guide block mounted upon the moving platen retains the stop bar and split ring with a clamping device. To set the mechanical safety device, move clamp to required mold open position and open front safety gate. Using the most available cylindrical groove, adjust the stop bar in the guide block to a position as close as possible to the strike plate.

NOTE! The safety device must be checked for correct adjustment every time the mold open stroke is altered. Ensure strike plate pivots freely. See warning plates attached to the machine.

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3. SAFETY DEVICES

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MAINTENANCE Mechanical Safety Type 2

MOVING PLATEN

STATIONARY PLATEN

SAFETY ROD

STOP BLOCK

TUBE

LATCH

STOP BLOCK

ROLLER

Mechanical Safety Device As Viewed From Above 1. 2.

3.

When the front safety gate is opened the latch drops into a groove in the safety rod thereby preventing the clamp from closing. As the front safety gate is closed the cam on the gate contacts the roller attached to the latch. This causes the latch to be lifted from the groove on the safety rod which then permits the clamp to close. This design requires no regular adjustment. However, it is essential to regularly check that the latch moves freely as the safety gate is opened and closed. This device must be kept clean of all debris.

Mechanical Safety Type 3

SAFETY ROD

SAFETY ROD MOVING PLATEN

BASE PLATE BRACKET LATCH LEVER SHAFT

1. 2.

3.

ROLLER

Mechanical Safety Device As Viewed From Above When the front safety gate is opened the latch drops into a groove in the safety rod thereby preventing the clamp from closing. As the front safety gate is closed the cam on the gate contacts the roller which is attached through the lever and the shaft to the latch. This causes the latch to be lifted away from the safety rod. The rod is then free to move through the base plate and the clamp permitted to close. This design requires no regular adjustment. However, it is essential to regularly check that the latch moves freely as the safety gate is opened and closed. This device must be kept clean of all debris.

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3. SAFETY DEVICES

91

MAINTENANCE Mechanical Safety Type 4

92

3. SAFETY DEVICES

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MAINTENANCE This type of Mechanical Safety Bar is fixed to the toggle crosshead or the moving platen and moves through the cylinder platen with each movement of the clamp. The latch and pneumatic actuator are mounted on the cylinder platen and are spring loaded into the latched position. A failure of the compressed air supply will result in the Mechanical Safety Device being in the locked position. When the safety gate is opened, the controller de-actuates the solenoid S45. This action divert compressed air into the piston side of the pneumatic latch and closes the latch onto the Mechanical Safety Device ratchet bar, assisted by the spring tension, preventing closure of the clamp. Closing the safety gate re-activates the solenoid S45 and this action diverts air to the rod side of the pneumatic latch and opens the latch, against the spring tension, freeing the mechanical safety device and allowing the clamp to close. The Mechanical Safety Device can be overridden (mold opening only) with the keyswitch CORES AND EJECTORS - MOTION / NO MOTION when switched into the MOTION position.

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3. SAFETY DEVICES

93

MAINTENANCE 2.1

SAMPLE MACHINE SAFETY CHECKLIST

SAFETY CHECKLIST YES NO INIT. INIT.

FUNCTION

REMARKS

1. DO LIMIT SWITCHES E3 & E4 ON THE REAR DOOR STOP THE MOTOR ? 2. IS THE MECHANICAL SAFETY DEVICE ADJUSTED CORRECTLY -DOES THE STRIKE PLATE DROP FREELY ? 3. DOES THE HYDRAULIC INTERLOCK STOP CLOSING OF THE PRESS ?

4. DO LIMIT SWITCHES E1 & E2 STOP THE CLOSING OF THE CLAMP ? 5. DOES THE EMERGENCY STOP BUTTON STOP THE MOTOR WHEN PRESSED ? 6. DOES AN OPEN GATE STOP CLAMP FROM CLOSING ? 7. IS THE HEAT SHIELD OVER THE BARREL INSTALLED ? 8. ARE THE HEAT CONTROL INSTRUMENTS FUNCTIONING PROPERLY ? 9. ARE THERE ANY OIL OR WATER LEAKS ?

10. IS SAFETY GATE ALARM CIRCUIT FUNCTIONAL ? 11. ARE ALL SAFETY WARNING LABELS ATTACHED TO MACHINE ? A7720451

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3. SAFETY DEVICES

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MAINTENANCE 2.2

ROTARY TABLE SAFETY FEATURES

EMERGENCY STOP

MECHANICAL HEAT SHIELD CLOSING SAFETY MAIN ELECTRICAL ISOLATOR

MFSI

PURGE SLIDE LIGHT CURTAIN or PNEUMATIC SAFETY GATE

PURGE GUARD

EMERGENCY STOP

NOTE! These safety features are typical but may vary with machine size and options.

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3. SAFETY DEVICES

95

MAINTENANCE 3.

ROTARY TABLE SAFETY FEATURES

These protective features are built into the machine to protect personnel. The user is responsible for each protective device being in good working order before the machine is placed in operation. The user must maintain these safety features in working order. Operational and maintenance personnel must be trained to recognize that variations in machine configuration (i.e. vertical or horizontal clamp), machine size and age may result in changes to the design and position of safety features and guards. We very strongly recommend that the safety features are inspected at the beginning of each shift and when a new mold is installed. A log should be kept detailing when and by whom the inspections were performed. Main Disconnect Switch • Operation of this switch to open the electrical cabinet door, cuts power downstream of the 107 disconnect switch. • L1, L2, and L3 entering the cabinet may still be live. • Check that operating the handle cuts power to machine. Emergency Stop Buttons • Pushing any one of these switches in will cause a break in the electric motor circuit causing the motor to stop. • Restart of the motor should not be possible until the button is released. • Check that motor stops when any one of these buttons is pressed. Mechanical Safety Device • Mechanically prevents clamp closure when the light curtain is interrupted. • A spring causes the stop bar to be engaged when the light curtain is interrupted, when the machine is in manual, or when pneumatic power is lost. • A pneumatic cylinder disengages the stop bar when the clamp is being operated. • A fault with the limit switch (B77) monitoring this device would be indicated by a "MECH.INTRLCK FAULT" error on the monitor. Light Curtain • Interruption of the light curtain will prevent clamp or ejector movements. • In manual mode check that clamp and ejector movement are prevented when the light curtain is being interrupted. • Run a finger slowly down the edge of the light curtain and check that as each beam is interrupted the "LIGHT CURTAIN HAZARD" warning light is illuminated. Mold Flash Safety Interlock (MFSI) • Provides operator protection during injection. • Prevents injection if mold is not closed. • Check that switch is made when mold halves are in contact and not before. • With B74 (Purge Slide closed) input made and K (nozzle back) position reached to allow for purging but with the Mold Flash Safety Interlock not made, check that manual injection is prevented.

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3. SAFETY DEVICES

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MAINTENANCE Purge Guard • Provides operator protection during purging. • De-activates limit switch E9 to prevent injection while guard is raised. • Check that raised purge guard prevents carriage movement. Purge Slide • Provides operator protection during purging. • Limit switch B74 (slide closed) must be made to allow purging. • With slide out of position but Mold Flash Safety Interlock input made and position K (nozzle back) reached check that manual injection is not possible. Barrel Heatshield • Provides operator protection from direct contact with heater bands. • Check that shields are in place before operating. Cover Around Clamp Assembly • Provides protection from the toggle mechanism while machine is in operation. • Check that opening either of the locking side panels stops the motor via limit switches E3 and E4. • Check that the other fixed panels are securely fastened in position.

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3. SAFETY DEVICES

97

MAINTENANCE 3.1

SAMPLE ROTARY MACHINE SAFETY CHECKLIST

ENGEL ROTARY SAFETY CHECKLIST DATE:

TIME:

SIGNED:

CHECKED BY:

FUNCTION

YES

NO

REMARKS

1. DOES THE MAIN DISCONNECT SWITCH CUT POWER TO THE MACHINE ? 2. DOES THE MOTOR STOP WHEN ANY ONE OF THE EMERGENCY STOP BUTTONS IS PRESSED ? 3. DOES AN INTERRUPTION OF THE LIGHT CURTAIN PREVENT BOTH CLAMP AND EJECTOR FUNCTIONS ? 4. IS INJECTION PREVENTED IF THE MOLD IS NOT CLOSED ? 5. IS CARRIAGE MOVEMENT AND INJECTION PREVENTED WITH RAISED PURGE GUARD ? 6. IS INJECTION PREVENTED IF THE PURGE SLIDE IS NOT CLOSED ? 7. DOES THE MOTOR STOP WHEN EITHER OF THE LOCKING CLAMP COVERS IS OPENED ?

8. ARE ALL COVERS SECURELY IN PLACE ?

9. IS THE BARREL HEATSHIELD IN PLACE ?

10. ARE THERE ANY OIL OR WATER LEAKS ?

11. ARE ANY WIRES DAMAGED OR ELECTRICAL CONNECTIONS EXPOSED ? 12. ARE ALL SAFETY WARNING LABELS ATTACHED TO MACHINE?

NOTE! This is a sample checklist and intended as a guide only. Certain machine options may require additions to, or deletions from the list.

98

3. SAFETY DEVICES

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MAINTENANCE 3.2

SHUTTLE TABLE SAFETY FEATURES

8 B77 8

1 5

AS

7

E9

6 4

4

B77 2

3

2

2

Find # 1 2 3 4 5 6 7 8 Switch E9 B77 AS

AS

Description Main Disconnect Switch on Electrical Cabinet Emergency Stop Buttons Mechanical Safety Device (Closing Protection) Light Curtain Front Safety Gate Purge Guard Heat Shield over Barrel Hard Cover around Clamp Assembly Limit Switch on Sliding Injection Guard Switch Indicating Mechanical Safety Engaged Switch Indicating Front Safety Gate Closed

NOTE! These safety features are typical but may vary with machine size and options.

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3. SAFETY DEVICES

99

MAINTENANCE 4.

SHUTTLE TABLE SAFETY FEATURES

These protective features are built into the machine to protect personnel. The user is responsible for each protective device being in good working order before the machine is placed in operation. The user must maintain these safety features in working order. Operational and maintenance personnel must be trained to recognize that variations in machine configuration (i.e. vertical or horizontal clamp), machine size and age may result in changes to the design and position of safety features and guards. It is strongly recommend that the safety features are inspected at the beginning of each shift and when a new mold is installed. A log book should be kept detailing when and by whom the inspections were performed. Main Disconnect Switch • Operation of this switch to open the electrical cabinet door, cuts power downstream of the 107 disconnect switch. • L1, L2, and L3 entering the cabinet may still be live. • Check that operating the handle cuts power to machine. Emergency Stop Buttons • Pushing any one of these switches in will cause a break in the electric motor circuit causing the motor to stop. • Restart of the motor should not be possible until the button is released. • Check that motor stops when any one of these buttons is pressed. Mechanical Safety Device • Mechanically prevents clamp closure when the light curtain is interrupted. • A spring causes the stop bar to be engaged when the light curtain is interrupted, when the machine is in manual, and when pneumatic power is lost. • A pneumatic cylinder disengages the stop bar when the clamp is being operated. • A fault with the limit switch (B77) monitoring this device would be indicated by a "MECH.INTRLCK FAULT" error on the monitor. Light Curtain • Interruption of the light curtain will prevent clamp or ejector movements. • In manual mode check that clamp and ejector movement are prevented when the light curtain is being interrupted. • Run a finger slowly down the edge of the light curtain and check that as each beam is interrupted the "LIGHT CURTAIN HAZARD" warning light is illuminated. Front Safety Gate • Provides operator protection during injection. • De-activates limit switch AS to prevent injection while gate is open. • Check that injection is prevented when gate is opened. (For the purpose of this check the gate must be open enough to release limit switch AS but not so far as to interrupt the light curtain).

100

3. SAFETY DEVICES

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MAINTENANCE Purge Guard • Provides operator protection during purging. • De-activates limit switch E9 to prevent injection while guard is raised. • Check that raised purge guard prevents carriage movement. Barrel Heatshield • Provides operator protection from direct contact with heater bands. • Check that shields are in place before operating. • Cover Around Clamp Assembly • Provides protection from the toggle mechanism while machine is in operation. • Check that all fixed panels are securely fastened in position. Cover Around Clamp Assembly • Provides protection from the toggle mechanism while machine is in operation. • Check that all fixed panels are securely fastened in position.

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3. SAFETY DEVICES

101

MAINTENANCE 4.1

SAMPLE SHUTTLE MACHINE SAFETY CHECKLIST

ENGEL SHUTTLE SAFETY CHECKLIST DATE:

CHECKED BY:

TIME:

FUNCTION

YES

SIGNED:

NO

REMARKS

1. DOES THE MAIN DISCONNECT SWITCH CUT POWER TO THE MACHINE?

2. DOES THE MOTOR STOP WHEN ANY ONE OF THE EMERGENCY STOP BUTTONS IS PRESSED ? 3. DOES AN INTERRUPTION OF THE LIGHT CURTAIN PREVENT BOTH CLAMP AND EJECTOR FUNCTIONS ? 4. IS INJECTION PREVENTED IF THE FRONT SAFETY GATE IS OPEN ?

5. IS CARRIAGE MOVEMENT AND INJECTION PREVENTED WITH RAISED PURGE GUARD ?

6. IS INJECTION PREVENTED IF THE PURGE SLIDE IS NOT CLOSED ?

7. ARE ALL COVERS SECURELY IN PLACE ?

8. IS THE BARREL HEATSHIELD IN PLACE ?

9. ARE THERE ANY OIL OR WATER LEAKS ?

10. ARE ANY WIRES DAMAGED OR ELECTRICAL CONNECTIONS EXPOSED ?

11. ARE ALL SAFETY WARNING LABELS ATTACHED TO MACHINE ?

NOTE! This is a sample checklist and intended as a guide only. Certain machine options may require additions to, or deletions from the list.

102

3. SAFETY DEVICES

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MAINTENANCE 5.

SAFETY INSTRUCTION PLATES AND LABELS

Safety instruction plates are fastened to your machine at strategic locations. Under no circumstances shall they be removed. They must be kept clean and readable. Operating and maintenance personnel must understand each safety instruction before they are permitted to work on the machine. This section includes "DANGER", "WARNING" and "CAUTION" signs used on ENGEL machines. These signs are used to indicate a potential hazard caused by the improper use, adjustment, maintenance, or removal of a safety device or guard. The following pages show samples of the signs and the positions on the machine where they may be found. 2

7

5

8

9

6

3 1 4

3

F1 F2

F3

F4

F5

7

8

9

ENT

4

5

6

ER

1

2

3

-

0

F6

F7

F8

!

. CLE AR

S A

!

ON OFF

CONT ROL

PR

MO

VOL

TOR

TAG E

CORES O UT

RETR ACT

OP EN

INCR EASE

BARREL O HEAT N

O N

MOLD

O

HEAT

N

MO TOR

OVER LOAD

BARREL HEAT MOLDPOWER HEAT HOPPER OF OF AU OP AU

I N

F

EJECTOR MOLD CLAMPING SEC FW URE D.

F TO

SE

UNL

EN TO

OAD

INJECTION RELE ASE

INJE CT

CLAMP MODE SELECT CONTROL VOLTAGE CLO MAN MOTOR O UAL

START N

FE ED CARRIAGE FW RETR D.

ACT

MOLD HEIGHT MODE SELECT CONTROL VOLTAGE MOTOR STOP EMERGENCY DECR MAN OF ST EASE UAL F OP

1 2

FIND # 1 2 3 4 5 6 7 8 9 10 11 12

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2

11

DESCRIPTION HIGH VOLTAGE CRUSHING INJURY HIGH SPEED MOVING PARTS HIGH PRESSURE FLUID MOLTEN MATERIAL HOT AREA ROTATING SCREW COMPLEX MACHINE FILTER CLEANING FILL PUMP-STARTUP STATIC SENSITIVE CSA DISCLAMER

1

10

12

9

DRAWING NUMBER C3401.0301 C3401.0307 C3401.0302 C3401.0306 C3401.0317 C3401.0312 C3401.0318 C3401.0315 EC98.723.6354B EC98.723.6356B EC98.723.6370B EC98.723.6355B

3. SAFETY DEVICES

103

MAINTENANCE NOTE! These warning labels are typical of an ENGEL machine but may vary with machine size and options.

HIGH VOLTAGE

High voltage. Before servicing turn off, lock out/tag out main power disconnect. Do not modify electric or hydraulic circuits unless authorized by manufacturer. Earth ground machine and electrical cabinet before turning on power. Failure to comply can cause shock, burns or death. HIGH SPEED MOVING PARTS

High speed moving parts. Do not operate with gates / guards removed or open. DO NOT REACH AROUND, UNDER, OVER OR THROUGH GATE / GUARDS while machine is operating. can cause crushing injury or death.

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3. SAFETY DEVICES

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MAINTENANCE HOT AREA

High voltage. Hot surface. Turn off and lock out main power disconnect, allow to cool before servicing. Can cause shock, severe burns or death.

MOLTEN MATERIAL

High pressure molten material. Stand clear and wear protective gear when purging and/or servicing injection system. Can cause severe burns.

WARNING MOLTEN PLASTIC IS EXTREMELY HOT AND WILL CAUSE SEVERE BURNS TO HUMAN FLESH. ALWAYS WEAR A FACESHIELD AND PROTECTIVE CLOTHING WHEN REMOVING BLOCKAGES IN INJECTION UNITS, THE MOLTEN PLASTIC MAY BE UNDER PRESSURE. UNLESS YOU ARE WEARING PROTECTIVE CLOTHING AND A FACESHIELD, NEVER LOOK DIRECTLY INTO AN ORIFICE (NOZZLE OR FEEDTHROAT) THAT MAY DISCHARGE MOLTEN PLASTIC UNDER PRESSURE.

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3. SAFETY DEVICES

105

MAINTENANCE ROTATING SCREW

Rotating screw. Do not operate with hopper removed or put hands or feet into opening. Serious bodily injury can occur.

CRUSHING INJURY

Crushing injury. High speed moving parts. When operator gate is open and keyswitch “Core and Ejector Motion” is turned to motion, do not reach into unguarded mold area where pinch points are created. Consult supervisor for instructions. Failure to follow safety procedures can cause injury.

106

3. SAFETY DEVICES

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MAINTENANCE COMPLEX MACHINE

Complex machine with hazards. Do not operate machine unless trained, read and understand the Maintenance/ Operator manual(s). Prior to start-up, test safety devices per instruction manual. Do not operate machine unless interlocks/safety devices are in place and function properly. Do not modify machine unless authorized by manufacturer. Failure to follow instructions could result in injury.

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3. SAFETY DEVICES

107

MAINTENANCE FILTER CLEANING

FILL PUMP

CSA DISCLAIMER

108

3. SAFETY DEVICES

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MAINTENANCE: 4. INSTALLATION This section details information for installing and removal/replacement of major components: • Machine Installation •

Machine levelling

•

Centering injection units

•

Torque specifications

•

Mold set up

•

Swivelling injection units

• Screw Removal and Replacement • Screw Tip Removal and Replacement • Barrel Removal and Replacement • Heater Band Installation

1.

MACHINE INSTALLATION

NOTE! The CUSTOMER is responsible for ensuring that the machine is level. The operation of an injection molding machine that has not been correctly levelled causes mechanical stresses to the machine. This could lead to tiebar breakage, improper mold clamping, flashing of the mold, excessive wear on bushings and the toggle system, or roller bearing platen support breakage.

NOTE! ENGEL does not advise lifting machines of 300 tons clampforce and above using the vibration mounts. Use an appropriate jack under the machine frame, positioned close to the mount being adjusted.

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4. INSTALLATION

109

MAINTENANCE: 1.1

INSTALLATION OF MACHINE MOUNTS

To install machine mounts; determine the type of mounts supplied with the machine (SUNNEX or UNISORB) and follow the instructions below.

WARNING! DO NOT USE “VARSOL” TYPE PRODUCTS TO CLEAN THE FLOOR, THESE PRODUCTS LEAVE A RESIDUE. 1.

Remove all oil, grease and debris from the floor where the mounts will be positioned.

2.

To clean the floor: use an industrial grade grease solvent followed by a household grease cutting cleaner. Lightly buff the floor with sandpaper to remove any shiny finish. Ensure that sufficient floor area is cleaned to allow the mount to be slid under the machine. There must be no dirt or grease under the mount.

3.

Keep the mounts wrapped until they are ready to be placed under the machine.

4.

Move the machine into the required location and raise the machine enough to allow the machine mount housings to be positioned under the mounting locations of the base. The bolt is removed from the housing.

5.

Align the bolt holes in the mount with the mounting holes in the machine frame.

6.

Insert the bolts with nut and washer through the machine frame and screw fully into the mount housing.

7.

Align the mounts with the machine frame.

8.

Repeat for all the mounting points and lower the machine onto the isolation mounts.

9.

Refer to the tables over the page for adjustment range of the type of mount being used.

10. Allow 20 minutes for the machine to “settle in” on the isolation mounts. 11. Refer to the attached levelling procedure for “TIEBARLESS” or “TIEBAR” machine. 12. Torque on the leveling bolts should be roughly equal, indicating an even load distribution. 13. When the machine is level, tighten the locknut to secure the mount to the machine frame.

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MAINTENANCE: 1.2

SUNNEX ISOLATION MOUNTS SUNNEX ISOLATION MOUNTS Mount type

Minimum height

ΤMaximum height

Adjustment range

M1

1.56” (39.6 mm)

2.06” (52.3 mm)

0.50” (12.7 mm)

M2

1.81” (46.0 mm)

2.31” (58.7 mm)

0.50” (12.7 mm)

HD30

2.09” (53.1 mm)

2.84” (72.2 mm)

0.75” (19.1 mm)

HD40

2.20” (55.9 mm)

2.95” (75.0 mm)

0.75” (19.1 mm)

NOTE! 1. Measure from the floor to the top of the levelling support plate 2. Never exceed the maximum height of the machine mount housing (Distance between floor and top surface of leveling support plate)! Add shims, as required, to deal with any floor irregularities. For additional adjustment range, use shims between the machine frame and the mount housing. The shims must have the same footprint as the leveling support plate.

A SECTIONAL VIEW THROUGH A TYPICAL SUNNEX ISOLATION MOUNT

ADJUSTING SPINDLE

MACHINE BASE

LOCKNUT LOCKWASHER

LEVELING SUPPORT PLATE

(Generic)

MACHINE MOUNT HOUSING

SEE TABLE FOR MAXIMUM HEIGHT

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4. INSTALLATION

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MAINTENANCE: 1.3

UNISORB ISOLATION MOUNTS

UNISORB QUANTUM® ISOLATION MOUNTS Mount type

Minimum height

Maximum height

Adjustment range

IM51

2.50” / 63.5 mm

3.88” / 98.5 mm

1.38” / 35.0 mm

IM61

2.50” / 63.5 mm

3.88” / 98.5 mm

1.38” / 35.0 mm

IM71

2.50” / 63.5 mm

3.88” / 98.5 mm

1.38” / 35.0 mm

IM81

2.50” / 63.5 mm

3.88” / 98.5 mm

1.38” / 35.0 mm

IM81TS

2.50” / 63.5 mm

3.25” / 82.5 mm

0.75” / 19.0 mm

NOTE! Never exceed maximum height of the machine mount housing (Distance between floor and top surface of machine mount)! Add shims as required to deal with any floor irregularities. For additional adjustment range, use shims between the machine frame and the mount housing. The shims must have the same footprint as the isolation mount.

ADJUSTING BOLT

LOCKNUT

A SECTIONAL VIEW THROUGH A TYPICAL QUANTUM ISOLATION MOUNT

LOCKWASHER MACHINE MOUNT HOUSING

MACHINE BASE (Generic)

SEE TABLE FOR MAXIMUM HIEGHT

PAD & IMPACT PLATE ASSEMBLY

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MAINTENANCE: 1.4

ADJUSTMENT OF MACHINE MOUNTS (TOGGLE MACHINE)

NOTE! ENGEL do not advise lifting machines of 300 tons clampforce and above using the vibration mounts. Use an appropriate jack under the machine frame, positioned close to the mount being adjusted. •

Use a precision machinist's level and adjust for an approximate level of 0.002" per foot lengthways and widthways on a convenient machined surface e.g. platen guides, tiebars injection guides .

•

Turn the adjustment spindle, or adjustment bolt, clockwise (cw) to raise the machine frame and counterclockwise (ccw) to lower the machine frame. Try to keep the space between the support plate and the mount housing to a minimum.

•

Check machine level on both frame and tiebars. (See section on Moving Platen Roller Bearing Supports, for machines so equipped.) When the machine has been levelled, tighten the isolation mount locknuts.

•

LEVEL FRAME LEVEL INJECTION GUIDES LEVEL TIE BARS

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MAINTENANCE: 1.5

ADJUSTMENT OF MACHINE MOUNTS (TIEBARLESS MACHINE)

NOTE! ENGEL do not advise lifting machines of 300 tons clampforce and above using the vibration mounts. Use an appropriate jack under the machine frame, positioned close to the mount being adjusted. • • • •

114

Using an engineer’s spirit level or a precision water level, check the level of the machine across and along the moving platen guide rails. Check the machine level along the injection unit guide rail. The machine must be level within approximately 0.002 inches per foot. Adjust the spindle, or adjustment bolt, of the machine support, clockwise to raise or anti clockwise to lower, the machine mount as necessary to achieve a level situation.

4. INSTALLATION

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MAINTENANCE: 1.6

SPLIT BASE MACHINE INSTALLATION

The CUSTOMER is responsible for ensuring that the machine is level. The levelling of a split base injection molding machine is even more important than that of a single base machine, an incorrectly levelled machine will cause excess mechanical stress to the machine. This could lead to tiebar breakage, improper mold clamping, flashing of the mold, excessive wear on bushings and the toggle system, or roller bearing platen support breakage. Equipment required. a.

Precision level accurate to 0.002" per foot.

b.

Machined flat steel bar approximately six foot long.

c.

Wrenches; open ended:

d.

Lubricating oil.

• • • •

20 mm 40 mm 50 mm 70 mm

Installation of Machine Mounts To install machine mounts; determine the type of mounts supplied with the machine: BARRY

follow the instructions below.

UNISORB

refer to the section entitled “Installation of machine mounts”

WARNING! Do not clean using a “Varsol”type product, this will leave a residue on the floor. 1. Remove all oil, grease and debris from the floor where the mounts will be positioned. 2. To clean the floor: use an industrial grade grease solvent followed by a household grease cutting cleaner. Lightly buff the floor with sandpaper to remove any shiny finish. Ensure that sufficient floor area is cleaned to allow the mount to be slid under the machine. There must be no dirt or grease under the mount. 3. Keep the mounts wrapped until they are ready to be used. 4. Remove locknut and washer from the threaded rod. 5. Turn the threaded rod so that the support plate and the mount housing come into contact. 6. Lubricate the mount and the threaded rod before installation. 7. Raise the Injection and Clamp base high enough to insert each machine mount. 8. If not already fitted, screw the threaded sleeve, with the 70 mm locknut fitted, into the machine base so that the end of the threaded sleeve is flush with the under side of the machine base. 9. Insert the threaded rod through the holes in the threaded sleeve fitted to the machine base and replace the locknut and washer. Do not tighten the locknuts. 10. Lower the Clamp and Injection bases onto their machine mounts, so that they are tightly butted together.

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MAINTENANCE: BARRY ISOLATION MOUNTS THREADED ROD

40 mm LOCKNUT WASHER

THREADED SLEEVE

70 mm LOCKNUT

MACHINE BASE

A

OILPROOF RUBBER ELASTIC ELEMENT

SUPPORT PLATE

MOUNT HOUSING

Adjustment of Isolation Machine Mounts

NOTE! For Barry mounts use step 4a If a combination of mounts are employed use step 4a for Barry mounts and step 4b for UNISORB mount 1. Using the Clamp and Injection base adjustable mounting pads #1 and #2, set the height of each base as necessary to align the Injection base with the spacer block on the Clamp base. 2. Level the separate bases along the length of the operator side first, followed by the nonoperator side, using only mounting pads #8 and #10. 3. Use a precision level and adjust for a level of approximately 0.002" per foot lengthways and widthways. 4a. Using a 50 mm wrench turn the threaded sleeve to raise the machine frame or lower the machine frame as necessary. Try to keep the space "A" (see figure above) between the support plate and the machine base to a minimum. 4b. Turn the adjustment spindle, or adjustment bolt, clockwise (cw) to raise the machine frame and counterclockwise (ccw) to lower the machine frame. Try to keep the space between the support plate and the mount housing to a minimum.

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MAINTENANCE: 5.

Check machine level across both frame and tiebars on the Clamp base, adjust using only mounting pads # 1, 2, 3, 4, 15 and 16. (See section on Moving Platen Roller Bearing Supports, for machines so equipped.) 6. Check machine level across the frame on the Injection base, adjust using only mounting pads # 1, 2, 8 and 10. 7. Turn threaded sleeves on machine pads #5 to 14 on the Clamp base and machine pads # 3 to 7 and #9 on the injection base, until the weight of the bases is supported plus and extra 1/ 4 turn. 8. Check again that the level is approximately 0.002" per foot lengthways and widthways, adjust as necessary. 9. Tighten all 70 mm locknuts on the threaded sleeves. 10. Tighten all 50 mm locknuts on the threaded rods. 11. When the machine has been levelled, tighten the locknuts.

OPERATOR SIDE LEVEL TIEBARS

LEVEL INJECTION GUIDES

LEVEL MACHINE FRAME

15 13

11

9

7

5

3 1

16 14

12

10

8

6

4 2

CLAMP BASE

1 2

3

7

5

9

10

6

8

4

INJECTION BASE

MACHINE MOUNTING PAD NUMBERS

NOTE! The number of machine mounting pads will vary with the size of Injection Molding machine, the figure is intended as a guide only

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MAINTENANCE: 2.

SPLIT BASE MACHINES - TIEBARLESS - INSTALLATION - EARLY STYLE

2.1

GENERAL

This section details information for mounting and levelling split base machines.

CAUTION! THE INJECTION MOLDING MACHINE MUST NOT BE LIFTED AS ONE ASSEMBLY, MOVE EACH BASE SEPARATELY! DISCONNECT YOKE AS INDICATED IN THE FIGURE BELOW

NOTE! The clamp base must be mounted and levelled first, then the injection base can be mounted and levelled to the clamp unit as described below. 1. Set the clamp base on the vibration mounts and level, refer to section “Machine installation” for installing mounts. 2. The yoke that connects the injection and clamp bases together, should already be mounted on the injection base, when shipped. 3. The yoke for a tiebarless machine base, should be oriented as shown below.

INJECTION UNIT BASE

NOTE; DISCONNECT YOKE HERE

NOTE: DO NOT DISCONNECT THE YOKE HERE When disconnecting the bases to move the machine.

CLAMP BASE

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MAINTENANCE: SET SCREWS

CAP SCREWS

MOUNTING BAR

YOKES - Mounted on injection unit

Typical yoke Raise or lower the injection base using a jacks and adjust the machine mount height until the yoke and the bar on the clamp frame line up. The machine bases were joined and levelled at the factory. The injection unit was adjusted until the single set screw coincided with the middle of the mounting bar on the clamp base.

NOTE! It is the customer responsibility to level the machine at the new location. This positioning is not critical, as long as the bar is captured within the yoke and the injection unit nozzle is centered within the locating ring of the stationary platen. Fine adjustments for nozzle centering can be made later at the eccentric cam adjusters on the injection unit carriage. There is +/-2mm adjustment on the injection unit. Mount the strap onto the yoke, tighten the cap screw “hand tight”, until the two bases have been levelled and then tighten the cap screws. The connection does not form part of the machine rigidity, although there is a small intermittent compressive load on the yoke. High torquing of this connection has no beneficial impact on performance or alignment. The “set screws” were set at the factory and should need no adjustment.

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MAINTENANCE:

COLLAR - Lateral alignment

INJECTION BASE

CLAMP BASE

YOKE

MOUNTING BAR

The lateral alignment is set at the factory. Two collars are fitted to the clamp unit mounting bar to permanently set the lateral alignment of the injection base to the clamp base.

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MAINTENANCE: 3.

SPLIT BASE MACHINE LEVELLING

NOTE! The CUSTOMER is responsible for ensuring that the machine is level. The levelling of a split base injection molding machine is even more important than that of a single base machine, an incorrectly levelled machine will cause excess mechanical stress to the machine. This could lead to tie-bar breakage, improper mold clamping, flashing of the mold, excessive wear on bushings and the toggle system, or roller bearing platen support breakage. Equipment required. • Precision level accurate to 0.002" per foot or better. • Machined flat steel bar approximately six foot long. • Wrench - open ended - 20 mm • Lubricating oil. • Suitable jack capable of lifting each base.

3.1

LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS

NOTE! ENGEL does not advise lifting machines of 300 tons clampforce and above using the vibration mounts. Use an appropriate jack under the machine frame, positioned close to the mount being adjusted.

NOTE! Level the clamp base first. 3.1.1 1. 2. 3. 4.

LEVELLING THE CLAMP BASE Level the clamp base along the length of the operator side first, followed by the nonoperator side. Use a precision level and adjust for a level of approximately 0.002" per foot. Turn the adjustment bolt, clockwise (cw) to raise the height of the machine frame and counterclockwise (ccw) to lower the height of the machine frame. Turn adjustment bolt on machine pads #5 and 6 on the Clamp base, until the weight of the base is supported, add an extra 1/4 turn.

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MAINTENANCE: 5.

Check and adjust the clamp base level across both frame and tie-bars, adjust the height using only mounting pads # 1, 2, 3 and 4, adjust in pairs for the eight mount Austrian machines. For Canadian machines, re-adjust mounting pads #5 and #6, if necessary, to take up the weight of the machine and add an extra 1/4 turn. Torque on the adjustment bolts should be roughly equal, indicating equal load on all the pads.

Typical Canadian machine mount layout

Typical Austrian machine mount layout

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MAINTENANCE:

Machine levelling 3.1.2

LEVELLING THE INJECTION BASE

1.

Level the injection base along the length of the operator side first, using mounts #8 and #10, followed by the non-operator side, using mounts #7 and #9. Using a precision level, adjust for a level of approximately 0.002" per foot. Turn the adjustment bolt, clockwise (cw) to raise the height of the machine frame and counterclockwise (ccw) to lower the height of the machine frame. The number of machine mounting pads will vary with the size of Injection Molding machine, the figure is intended as a guide only

2.

Introduce the injection unit base to the clamp unit base. Raise or lower all machine mounts on the injection base to line up the yoke with the bar on the clamp frame. Lining up the yoke to be equidistant over the bar will ensure that the injection unit is approximately at the right height relative to the clamp unit. The customer will still have to ensure that the machine is level.

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MAINTENANCE:

Roughly equal space above and below the bar

3.

When the two bases are connected, check the level in both planes. If the level is within the 0.002 inches per foot the spacers can be tightened to the clamp base. Use the torque specifications in the found in the section “Torque specifications”.

4.

Check that the level is still approximately 0.002" per foot lengthways and widthways, adjust as necessary.

5.

When the machine is level, tighten the machine mount lock nuts.

6.

Refer to the following sections “Centering the injection unit” for checking and adjusting nozzle alignment.

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MAINTENANCE: 4.

SPLIT BASE - TIEBARLESS - INSTALLATION - LATER STYLE

4.1

GENERAL

This section details information for mounting and levelling split base machines.

WARNING! THE INJECTION MOLDING MACHINE MUST NOT BE LIFTED AS ONE ASSEMBLY! MOVE EACH BASE SEPARATELY!

CAUTION! DO NOT DISCONNECT THE BASE ASSEMBLIES AT THE INJECTION UNIT END, ALWAYS DISCONNECT AT THE CLAMP UNIT

NOTE! The clamp base must be mounted and levelled first, then the injection base can be mounted and levelled to the clamp unit as described below. 1. Set the clamp base on the vibration mounts and level, refer to section “Machine installation” for installing mounts. 2. On a typical machine base the mounting blocks are as shown below. If a larger injection unit is used, spacers may have to be fitted to the mounting blocks to accommodate the longer barrel. In this case the spacers will be fitted at the factory and shipped mounted to the injection unit and should not be removed under any circumstance.

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MAINTENANCE:

Typical clamp unit mounting bar Raise or lower the injection base until the dowel on the injection unit block or spacer and the slot in mounting bar on the clamp frame line up. This dowel is inserted at the factory and sets up the lateral align of the bases. The slots on the mounting bar allow a certain amount of vertical adjustment for the injection unit base. Raise or lower the injection unit until the nozzle roughly coincides with the center of the stationary platen ring. The fine adjustment can be done at the injection unit Level the injection base in the same manner as the clamp base, see section entitled “Split base levelling” Insert bolts and torque as usual. Grade 12.9, M20 x 90 socket head cap screws are used to join the two bases. Because the material that the screw is being threaded into is not high tensile, ENGEL recommend using torque values for grade 10.9 socket head cap screw, to reduce the risk of thread distortion in the tapped hole.

NOTE! There is a small intermittent compressive load on these spacers. High torquing of this connection has no beneficial impact on performance or alignment.

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MAINTENANCE: 5.

SPLIT BASE MACHINE LEVELLING

NOTE! The CUSTOMER is responsible for ensuring that the machine is level. The levelling of a split base injection molding machine is even more important than that of a single base machine, an incorrectly levelled machine will cause excess mechanical stress to the machine. This could lead to tie-bar breakage, improper mold clamping, flashing of the mold, excessive wear on bushings and the toggle system, or roller bearing platen support breakage. Equipment required. • Precision level accurate to 0.002" per foot or better. • Machined flat steel bar approximately six foot long. • Wrench - open ended - 20 mm • Lubricating oil. • Suitable jack capable of lifting each base.

5.1

LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS

NOTE! ENGEL does not advise lifting machines of 300 tons clampforce and above using the vibration mounts. Use an appropriate jack under the machine frame, positioned close to the mount being adjusted.

NOTE! Level the clamp base first. 5.1.1 LEVELLING THE CLAMP BASE 1. Level the clamp base along the length of the operator side first, followed by the nonoperator side. 2. Use a precision level and adjust for a level of approximately 0.002" per foot. 3. Lift the machine frame with an appropriate jack, if the machine is 300 tons clampforce or over. Turn the adjustment bolt, clockwise (cw), on the machine mount, to raise the height of the machine frame and counterclockwise (ccw) to reduce the height of the machine frame. 4. Adjustment machine mounts #5 and 6 on the Clamp base, until the weight of the base is supported, add an extra 1/4 turn.

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MAINTENANCE: 5.

Check and adjust the clamp base level across both frame and tie-bars, adjust using only mounting pads # 1, 2, 3 and 4, adjust in pairs for the eight mount Austrian machines. For Canadian machines, re-adjust mounting pads #5 and #6, if necessary, to take up the weight of the machine and add an extra 1/4 turn. Torque on the adjustment bolts should be roughly equal, indicating equal load on all the pads.

Typical Canadian machine mount location

Typical Austrian machine mount location

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MAINTENANCE:

Machine levelling points 5.1.2 1.

2. 3.

4. 5.

LEVELLING THE INJECTION BASE Level the injection base along the length of the operator side first, using mounts #8 and #10, followed by the non-operator side, using mounts #7 and #9. Using a precision level, adjust for a level of approximately 0.002" per foot. Use an hydraulic jack to raise and lower the injection base. Turn the adjustment bolt, clockwise (cw) to increase the base height frame and counterclockwise (ccw) to lower the base height. The number of machine mounting pads will vary with the size of Injection Molding machine, the figure is intended as a guide only Introduce the injection unit base to the clamp unit base. Raise or lower the injection base to line up the blocks or spacers with the mounting bar on the clamp frame. Center the injection nozzle within the locating ring of the stationary platen. When the nozzle is centered, check the level in both planes. If the level is within the 0.002 inches per foot the spacers can be tightened to the clamp base. Use the torque specifications in the found in the section “Torque specifications”. When the machine is level, tighten the machine mount lock nuts. Refer to the following sections “Centering the injection unit” for checking and adjusting nozzle alignment. The injection carriage has eccentric cam adjusters that will give +/-2 mm of movement to center the nozzle accurately.

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MAINTENANCE: 6.

VERTICAL CLAMP - MACHINE LEVELLING

NOTE! The CUSTOMER is responsible for ensuring that the machine is level. The levelling of the injection molding machine is important, as an incorrectly levelled machine will cause excess mechanical stress on the machine components. This could lead to, improper mold clamping, flashing of the mold and excessive wear on bushings. Equipment required: • Precision level accurate to 0.002" per foot or better. • Machined, flat steel bar, approximately six foot long. • Wrench - open ended - 20 mm • Lubricating oil. • Suitable jack capable of lifting each base. LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS

NOTE! ENGEL does not advise using the vibration mounts to lift machines of 300 tons clampforce and above. Use an appropriate jack under the machine frame, positioned close to the mount being adjusted.

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MAINTENANCE: LEVELLING THE ROTARY TABLE Level the table, using machine mounts 1 and 2 inconjunction with mounts 3 and 4. Use a engineer’s precision level and adjust for a level of approximately 0.002" per foot. Lift the machine frame with an appropriate jack, if the machine is 300 tons clampforce or over. Turn the adjustment bolt, clockwise (cw), on the machine mount, to raise the height of the machine frame and counterclockwise (ccw) to reduce the height of the machine frame. Adjustment machine mounts #5, #6, #7, #8, #9 and #10, until the weight of the machine is supported, add an extra 1/4 turn. Check and adjust the level across the table, adjust using only mounting pads # 1, and 3 or 2 and 4, adjust in pairs. Check and adjust the table level in line with the machine, adjust using only mounting pads #1 and 2 or 3 and 4, adjust in pairs Torque on the adjustment bolts should be roughly equal, indicating equal load on all the pads.

CHECKING THE LEVEL AT THE INJECTION UNIT Level the injection base along the length of the operator side first, using mounts #8 and #10, followed by the non-operator side, using mounts #7 and #9. Using a precision level, adjust for a level of approximately 0.002" per foot. Use an hydraulic jack to raise and lower the injection base. Turn the adjustment bolt, clockwise (cw) to increase the base height frame and counterclockwise (ccw) to lower the base height. The number of machine mounting pads will vary with the size of Injection Molding machine, the figure is intended as a guide only When the machine is level, tighten the machine mount lock nuts.

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MAINTENANCE: 7.

INSTALLING AND SET-UP OF MOLD

Installing a mold in the Engel injection molding machine:

NOTE! Before lifting the mold into position ensure that the two halves are securely fastened together with straps or tie plates.

7.1

SECURING THE MOLD.

Direct bolting. Direct bolting is the most desirable method as the bolts not only carry the load of the mold but also resist the mold opening forces. Use bolts where the thread engagement is a minimum of 1 1/2 times the diameter of the bolt and lubricate the threads. Long spans between fixing points should be avoided and only high tensile alloy steel bolts of grade 8 or better should be used. The size and quantity of bolts used is determined by several factors: • The size of the threaded hole in the platen or mold. • The physical size of the mold. • The physical properties of the bolt. • Sufficient bolts to ensure the security of the mold. • Sufficient bolts to ensure that the mold opening forces can be resisted. Clamping. If clamps are used they must be of a type designed to be used with a particular mold, and the bolts securing the mold and clamp must be placed as close as possible to the mold. The bolts must be tightened so to prevent the mold moving during operation. As with the direct bolting method, the bolts must be of high tensile steel alloy of grade 8 or better and the threads must be lubricated. It is the machine users responsibility to determine the type and amount of bolts or clamps used to secure a particular mold. Once these criteria have been established proceed with mounting the mold as follows:

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MAINTENANCE: 7.2

INSTALLING MOLD

1.

Set velocity and pressure to a minimum by activating the set-up mode on the program selection panel.

2.

Ensure that the ejector rods are not in the way.

3.

Open the clamp to allow plenty of room to install the mold.

4.

Lower the mold into position and insert the location ring, located on the mold, into the insertion ring (female end), located on the stationary platen.

5.

(Toggle machines only) Still in the set-up mode, switch to the mold closing page and turn the automatic mold height adjustment program on. Turn the manual clamp switch to the “close’ position and hold the switch in the ‘close” position until the automatic mold height adjustment program switches off. At this point the toggle should be locked and the mold held between the two platens.

6.

(Direct hydraulic machines only) Still in the set-up mode, switch to the mold closing page and turn the manual clamp switch to the “close” position. Hold the switch in the “close” position until the moving platen touches the back of the mold and the actual mold position SFx = 0 (at least 5 seconds). At this point the mold should be held between the two platens.

7.

Turn the motor(s) and control voltage off and use an approved lockout procedure to ensure the machine is disabled. Check that clamp controls are disabled.

8.

Using the proper bolts and clamps, fasten the mold to the platens. The mold bolts should be screwed into the platens to a depth of at least one and a half times their diameter. For example, a 0.75 inch bolt should be screwed into the platen at least 1.125 inches. (i.e. 75 x 1.5 = 1.125).

NOTE! Refer to section 18 for approximate torque values. A selection of the most commonly used U.N.C. bolts, on standard SPI platens, are listed. 9.

Any additional equipment, such as water lines, should be connected at this time.

10. When the mold installation is secure and complete then the machine lockout may be removed and the machine restarted.

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MAINTENANCE: 8.

SETTING CLAMP FORCE

Toggle

NOTE! If the START CLAMPING PRESSURE variable G2 has been set correctly prior to adjusting the tonnage, G2 must be increased at each decrease of the mold height. Adjust G2 so that CLAMPING PRESSURE variable P1 activates just as the two mold halves touch. 1. 2. 3.

Set the program selection to the manual mode On the clamp force page, enter the required clamping force in the "Set" data field. 'P1' must always be set to 100%. Open and close the mold so that an "Actual" value of clamping force appears on the screen. The actual value will be compared with the set value and the automatic clamp force adjustment program will cause an adjustment by the mold height motor until the actual value of the clamping force is within the allowed tolerance range as set by K0285. Within this tolerance range there is no clamping force adjustment.

Toggle without clamp force transducer 1. Set the program selection to the manual mode. 2. Set clamping pressure (P1) to 100% 3. Use the mold height key switch to manually adjust the mold height increase or decrease. 4. Decrease the mold height until the toggle just barely locks in. This is the maximum clamp force for the machine. 5. If the machine is not equipped with a clamp force transducer, a reduction in tonnage can be accomplished by reducing 'P1' and following steps (3) and (4). For example, a 300 Ton machine can be adjusted to approximately 150 Tons by reducing P1 to 50%. Direct Hydraulic 1. Set the amount of tonnage desired in the CLAMP FORCE SET data field. The machine clamping pressure will be automatically adjusted according to the tonnage desired.

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MAINTENANCE: 9.

SETTING MOLD PROTECTION PRESSURE.

NOTE!

1. 2. 3. 4. 5.

6. 7.

This method of mold protection pressure setting only applies to Software system versions less than 2.00, refer to next section - 5 “Mold protection” Set mold protection pressure to 75%. Set all mold closing and mold protection speeds, equal to the mold protection speed desired. Set the distance of mold protection by adjusting mold protection start position, G1. Close and lock the mold while monitoring mold protection time variable, ZFx. Decrease the mold protection pressure until ZFx starts to increase. It is at this point that mold protection speed becomes pressure dependent and indicates the correct pressure setting for mold protection pressure. Mold protection can be made more sensitive, but only at the expense of a longer mold protection time and therefore a longer cycle time. Set the mold closing speeds as desired, but remember to use the last speed to slow down the mold as it enters the mold protection zone. This will guarantee that the mold is moving through the mold protection zone regulated by mold protection pressure and not the inertia of the mold's forward movement.

10.

MOLD PROTECTION

CC100 A03 controllers with “system version 2.00” or greater installed have the “Autoprotect” mold protection program installed. Controllers with “system versions” less than 2.00 do not have the “Autoprotect” program installed. The “Autoprotect” program monitors either the speed or pressure during mold closing between G1 and G2 and compares the data to a previously recorded successful mold closing. If the speed or pressure vary by a predetermined tolerance, a mold protection alarm is set. To check your machines software version: 1. Press the “Error message” key on the front panel. 2. Press F3 - “Hardware test” function key. 3. Press F4 - “SW version” function key. The first line will indicate the CPU type and “system version”, for example: • CPU 211 #1 SYS-V 1.17b - this machine DOES NOT have the “Autoprotect” program. or • CPU 212 #1 SYS-V 2.00 - this machine DOES have the “Autoptotect” program.

NOTE! Refer to the Controller - Operator manual for a control specific mold protection set-up procedure.

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135

MAINTENANCE: 11.

MOLD OPEN - STROKE LIMITATION ADJUSTING SPINDLE STANDARD MOLD CYLINDER KEY

CLOSING CYLINDER

SPINDLE

LOCK NUT

"Mold Open" Stroke Limitation adjustment procedure. To limit the "mold open" stroke, follow the steps laid out below: 1. Release the lock nut. 2. Turn the end of the spindle in an anti clockwise direction to achieve the fully retracted position. 3. Set the machine into the "Set up" mode. 4. Open the mold to the desired position (SFx = Platen position actual value). 5. Turn the spindle end clockwise until the adjusting spindle makes contact with the mold closing piston. 6. Contact between the piston and the adjusting spindle has been made when the spindle becomes difficult to turn. DO NOT continue to turn spindle once initial contact has been made. 7. Tighten the lock nut to lock the adjusting spindle in position. 8. Reduce the last mold opening speed (V8) and mold opening speed range (W2-A) to a level that will not cause the mold to bounce out of position.

NOTE! To correctly calibrate the mold stroke, it is necessary to fully retract the stroke limiter.

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4. INSTALLATION

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MAINTENANCE: FRONTPLATE

DAMPING RING

MACHINE COVER

TOGGLE CROSSHEAD

CAP SCREWS ADJUSTABLE TIEBAR

LOCKING BLOCK

ADJUSTING SPINDLES

"Mold Open" Stroke Limitation adjustment procedure. To limit the "mold open" stroke, follow the steps laid out below: 3. Release the cap screws in the locking block. 4. Retract both adjusting spindles to be level with the inside face of the frontplate. 5. Set the machine into the "Set up" mode. 6. Open the mold to the desired position (SFx = Platen position actual value). 7. Adjust both spindles until they both make contact with the toggle crosshead, DO NOT continue to turn spindles once initial contact has been made. 8. Tighten the cap screws in the locking blocks to hold the spindles in position. 9. Reduce the last mold opening speed (V8) and mold opening speed range (W2-A) to a level that will not cause the mold to bounce out of position.

NOTE! To correctly calibrate the mold stroke, it is necessary to fully retract the stroke limiters.

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137

MAINTENANCE: 12.

REMOVAL AND REPLACEMENT OF INJECTION SCREW.

Preparing machine for screw removal. For safe screw removal the following steps must be carried out: • Wait until the plasticizing cylinder is at operating temperature. • Push the hopper back to prevent feeding of the plastic material. • Ensure the purge guard is in place. • Operate the nozzle back switch to fully retract carriage.

WARNING! When handling a hot barrel or screw, wear asbestos gloves.

NOTE! If abrasive plastics have previously been molded, use a purging compound or Polyethylene to aid in purging the barrel. • Operate the Injection feed switch to purge the barrel, removing as much plastic material as possible. • At the controller, set "C4 - decompression before refill" to the maximum value to allow full screw retraction without screw rotation. Screw removal. When the machine has been properly prepared, proceed with the following steps:

WARNING!

• • • • • • •

Turn the power off and lock out to prevent accidental movement of the screw drive mechanism or coupling, when reaching into these areas. Operate the injection feed switch to fully retract the injection ram. Gain access to the barrel head area, lift or open purge guard. Disconnect the nozzle heater band and corresponding thermocouple. Loosen, but do not remove the front heater band. Remove the barrel head bolts. Remove the barrel head flange and nozzle. Remove the cover from the screw locking ring area.

NOTE! Do not remove locking ring. • Loosen the three socket screws on the locking ring and rotate clockwise to unlock (page 140)

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4. INSTALLATION

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MAINTENANCE: • • • • • • • • • • • • • •

Close the purge guard, this action sets digital input E9 high to allow screw movement. At the controller set the injection speeds to 0.5 inches per second. Operate the Injection switch to move the screw forward to 0.0 inches. Operate the injection feed back switch to uncouple the screw from the injection ram Disconnect both carriage retraction rods from the stationary platen (See pages 146 and 151). Open the purge guard. Fully swivel the barrel, refer to the section “swivelling the injection unit” for the method that applies to your machine. Close the purge guard. This action sets digital input E9 high to allow screw movement. An assistant will be required to hold the E52 limit switch (located on the non-operator side of the carriage) in its normal operating position to allow the injection ram to be operated. Introduce a brass bar (smaller in diameter than the inside diameter of the barrel) between the end of the screw and the injection ram. To expose the end of the screw, operate the Injection switch to move the Injection ram forward against the bar of metal to push the end of the screw out of the barrel. Operate the Injection feed switch to retract the Injection ram and remove the bar of metal. Release the E52 limit switch. Depending upon the size of the screw either, remove by hand or use a mechanical handling device.

Preparing machine for replacement of screw. Before the Injection screw can be replaced ensure that: • The inside of barrel is clean and free from obstructions. • The barrel is swivelled to the operators side. Replacement of screw. When the machine has been properly prepared, proceed with the following steps: • By hand or with a mechanical handling device, introduce the splined end of the screw into the barrel opening. • Supporting the front end of the screw, push the screw fully into the barrel. • Align the splines on the end of the screw with the splines in the Injection ram. • Open the purge guard. • Swivel the carriage, by hand, into alignment with the machine. • Connect the carriage retraction rods to the stationary platen (see pages 146 and 151). • Reduce all hydraulic operating pressures to minimum level. • Close the purge guard. • Operate Injection switch to gently push screw back into the splines of the Injection ram. • Turn locking ring anti-clockwise and tighten the three screws (See page 140 and Table 4.1 on page 159). • Open the purge guard • Fit barrel head flange and nozzle. • Fit barrel head bolts and tighten (See Table 4.1 on page 159). • Connect nozzle heater band and thermocouple. • Tighten front heater band. • Close purge guard.

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139

MAINTENANCE:

STATIONARY PLATEN SCREW

GRUB SCREW AND LOCKNUT

LOCKRING

TYPICAL SMALL INJECTION UNIT CARRIAGE

UNLOCK

INJECTION SCREW

LOCKING RING

LOCK

SCREW / LOCKING RING ARRANGEMENT

140

4. INSTALLATION

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MAINTENANCE: CARRIAGE RETRACTION ROD COUPLING

INJECTION SCREW

SOCKET SCREW LOCKING RING

STATIONARY PLATEN

CARRIAGE RETAINING SCREW

GUIDE PLATE

CARRIAGE RETAINING SCREW

PNEUMATIC CONNECTION

TYPICAL LARGE INJECTION UNIT - OLDER STYLE

TO MOVE UNIT LEVER POINT ECCENTRIC CAM ADJUSTER

CAM ADJUSTER ALLEN SCREW CLAMP

REAR INJECTION UNIT MOUNT

FRONT INJECTION UNIT MOUNT LOCKING HANDLE

TYPICAL LARGE INJECTION UNIT - NEWER STYLE

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4. INSTALLATION

141

MAINTENANCE: 13.

BARREL REMOVAL AND REPLACEMENT INJECTION UNITS 80-330).

Preparing machine for barrel removal. For safe barrel removal the following steps must be carried out: • Wait until the plasticizing cylinder is at operating temperature. • Push the hopper back to prevent feeding of the plastic material. • Ensure the purge guard is in place. • Operate the nozzle-back switch to fully retract carriage.

WARNING! Under normal operation the barrel is hot, and contains molten plastic, wear asbestos gloves when handling.

NOTE! If abrasive plastics have previously been molded, use a purging compound or Polyethylene to aid in purging the barrel. • Operate the Injection-feed switch to purge the barrel, removing as much plastic material as possible. • At the controller, set "C4 - decompression before refill" to the maximum value to allow full screw retraction without screw rotation. Barrel removal. When the machine has been properly prepared, proceed with the following steps:

WARNING! Turn the power off and lock out to prevent accidental movement of the screw drive mechanism or coupling, when reaching into these areas. • Operate the injection feed switch to fully retract the injection ram. • Remove the cover from the screw locking ring area.

NOTE! Do not remove locking ring. • Loosen the three socket screws on the locking ring and rotate clockwise to unlock (page 140) • At the controller set the injection speeds to 0.5 inches per second. • Operate the Injection switch to move the screw forward to 0.0 inches.

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4. INSTALLATION

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MAINTENANCE: • • • • • • •

Operate the injection feed back switch to uncouple the screw from the injection ram Disconnect both carriage retraction rods from the stationary platen (see pages 146 and 151). Open the purge guard. Fully swivel the barrel, by hand, towards the operator side of the machine. Disconnect all heater and thermocouple cables at plug panel. Fit two "eye" bolts into the top of the barrel, and attach with suitable lifting tackle to a crane. Release barrel "fast mounting " device as follows: • Remove safety screw from lever. • Open lever to maximum. • With the barrel suspended by the crane, gently pull barrel away from carriage. Preparing machine for replacement of barrel. Before the barrel can be replaced ensure that: • The carriage is swiveled to the operators side. Replacement of barrel. When the machine has been properly prepared, proceed with the following steps: • With the barrel suspended from a suitable crane, introduce the end of the barrel into the carriage opening. • Align the splines on the end of the screw with the splines in the Injection ram. • Turn locking ring anti-clockwise and tighten the three screws (See Table 4.1 on page 159). • Align the cut outs on the sides of the barrel with the jaws of the barrel "fast clamping" device, and close the clamp and replace the safety screw. • Open the purge guard. • Swivel the carriage, by hand, into alignment with the machine. • Connect the carriage retraction rods to the stationary platen (see pages 146 and 151). • Close the purge guard. • Connect the heater and thermocouple cables

STATIONARY PLATEN

FAST MOUNTING DEVICE

LIFTING EYE BOLTS SCREW

GRUB SCREW AND LOCKNUT

LOCKRING

Figure 4.11

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MAINTENANCE: 13.1

CENTERING THE 80 - 330 INJECTION UNIT - OLDER STYLE

Before carrying out any adjustments or measurements, bring the cylinder up to operation temperature

1 2

3

4

5

Locating Ring View X

6 7 8

1. Stationary Platen 3. Mounting Flange Screw 5. Lock Nut - Carriage Rod 7. Vertical Adjustment Nut

2. Mounting Flange 4. Carriage Rod Adjustment 6. Locking Set Screw 8. Lock Nut - Vertical Adjustment

Locating Ring View X

The machine must be operated with the injection unit centered and in-line with the sprue bushing. Measurement of nozzle centering. When the cylinder has reached operating temperature (approx. 200oC) move the nozzle in line with the surface of the stationary platen (1). Using a vernier caliper, measure vertically and horizontally the distance from the nozzle aperture to the edge of the central hole in the platen. The maximum off center tolerance is 0.008" (0.2 mm). If the nozzle is outside the maximum tolerance the following adjustments can be made: If adjustment is required: 1. Loosen the mounting flange screws (3) on both mounting flanges (2). 2. Loosen the lock nut - vertical adjustment (8). 3. Turn the vertical adjustment nut (7) to correct vertical position. 4. Slight horizontal adjustment (side to side) is possible by moving the mounting flanges (2). After centering, tighten the locknut for vertical adjustment (8) and mounting flange screws (3). If the injection unit is subject to "yawing" on contact, loosen the lock nut - carriage rod (5) and adjust the carriage rod (4). Re-tighten the lock nut after adjustment.

144

4. INSTALLATION

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MAINTENANCE: 13.2 CENTERING THE 80 - 330 INJECTION UNIT - NEWER STYLE

NOTE! Before carrying out any adjustments or measurements, bring the cylinder up to operation temperature

13.2.1 MEASUREMENT OF NOZZLE CENTERING. When the cylinder has reached operating temperature (approx. 200oC) move the nozzle (1) in line with the surface of the stationary platen (2). Using a vernier caliper, measure vertically and horizontally the distance from the nozzle aperture to the edge of the central hole in the platen. The maximum off center tolerance is 0.008" (0.2 mm). Ensure that the injection unit is level as well as centered. If the nozzle is outside the maximum tolerance the following adjustments can be made. Raising, lowering or levelling the injection unit is achieved by following the procedure below: 1. Loosen the four locating screw (1 or 2 turns). 2. Release the four locknuts. 3. Use the four adjustment bolts to raise or lower the unit to center the nozzle. 4. Place an engineers spirit level across the feedthroat. This is a machined flat surface. Turn the adjustment bolts as required to level the unit. Place the spirit level across and in line with the injection unit to determine the level in both planes. Once the injection unit is level, ensure that the nozzle is still centered. 5. Tighten the locknuts and locating screws when the desired position is achieved

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MAINTENANCE: The centering procedure may cause the injection unit to yaw (move to the side), if so, adjust as follows: 1. Run the nozzle to within 1/2" of the mechanical stop. 2. Remove the “Detent pin” and “Shoulder pin” from the coupling rod on the operator side. 3. Run the nozzle to the mechanical stop. 4. Loosen the locknuts on the carriage cylinder coupling rod. 5. Turn the “Adjustment nut” until the hole in the Joint is aligned with the hole in the Coupling Rod mounts. 6. Insert the Shoulder Pin and secure with the Detent Pin. 7. Secure the Connecting Rod with the Locknuts. Run the injection nozzle up to sprue bushing to check that the injection unit is not pulled as the nozzle pressure is applied.

LOCKNUTS INJECTION UNIT SIDE

CLAMP SIDE

ADJUSTMENT 13.2.2

SWIVELLING THE INJECTION UNIT

Refer to the procedure for screw or barrel removal. Prepare the injection unit for screw or barrel remove before swivelling. Release the “locknuts” and loosen the grub screws until the “retraction rod” can be released from the mount. Pull the injection unit towards the operator side. Grubscrew Locknut

Mounting Screws

146

4. INSTALLATION

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MAINTENANCE: 13.3 CENTERING THE NOZZLE - 650 AND UP - PREVIOUS STYLE INJECTION UNIT

NOTE! Before carrying out any adjustments or measurements, bring the barrel up to operation temperature 1

8 9 10

3

4 3 13 2

4 12 A3001479

11 5a

1 4 6 9 12

Nozzle Level Locknut Carriage Retaining Bolt Coupling Rod Joint Detent Pin

2 5a 7 10 13

6

Stationary Platen Level Nut -Nozzle side Stop screw Coupling Rod Coupling Rod Locknut

7

3 5b 8 11

6

5b

Measurement Level Nut - Inj. cyl. side Coupling Rod Shoulder Pin Coupling Rod Mounts

Nozzle centering measurement. When the barrel has reached operating temperature (approx. 200oC) move the nozzle (1) in line with the surface of the stationary platen (2). Using a vernier caliper, measure vertically and horizontally the distance from the nozzle aperture to the edge of the central hole in the platen. The maximum off center tolerance is 0.008" (0.2 mm). If the nozzle is outside the maximum tolerance the following adjustments can be made: 1. For vertical adjustments: a. Loosen the four Level Locknuts (4) on the injection cylinder unit. b. Turn the Level Nuts (5a and 5b) equal amounts to raise or lower the injection cylinder. c. Check the measurements are within the 0.008" tolerance of each other. d. Tighten the Locknuts (4). 1. When the desired vertical position is obtained tighten the Allen screw clamps

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4. INSTALLATION

147

MAINTENANCE: 14.

CENTERING THE INJECTION UNIT

14.1 CENTERING AND LEVELLING INJECTION UNITS - 650 AND UP - LATEST STYLE Specialized equipment required: • Engineers spirit level - 0.002" graduations per foot or better. • Vernier caliper • Suitable hydraulic jack capable of lifting one side of the clamp base.

NOTE!

1. 2. 3. 4. 5. 6. 7.

Ensure that the injection molding machine base and linear bearings are level. The items above must be level before attempting to level the injection unit. Remove the stationary half of the mold to expose the locating ring in the stationary platen. Move the injection unit forward until the nozzle is just protruding beyond the mounting face of the stationary platen. Move the screw back. Place an engineer's spirit level on the top of the "operator side" injection rod. Release the Allen screw clamps on the eccentric cam adjuster. Adjust the front or rear eccentric cams as required to level the injection unit. When the injection unit is level (to within 0.002" per foot) tighten the Allen screw clamp.

NOTE There is a total adjustment of 4 mm via the eccentric cam.

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4. INSTALLATION

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MAINTENANCE: 14.1.1

MEASUREMENT OF NOZZLE CENTERING. When the cylinder has reached operating temperature (approx. 200oC) move the nozzle in line with the surface of the stationary platen. Using a vernier caliper, measure vertically and horizontally the distance from the nozzle aperture to the edge of the central hole in the platen. The maximum off center tolerance is 0.008" (0.2 mm).

14.1.2

CENTERING THE NOZZLE.

To move the injection unit in the vertical plane: 1. Release the Allen screw clamps. 2. Adjust the eccentric cams simultaneously to raise or lower the unit. 3. When the desired vertical position is obtained tighten the Allen screw clamps To move the injection unit in the horizontal plane: 1. Release the four socket head cap screws under the front injection unit mount. 2. Release the two socket head cap screws under the rear injection unit mount. To move the injection unit towards operator: 1. On the non-operator side of the front injection mount, release the grub screw lock nut. 2. Using an Allen key, turn the grub screw in (cw) to push the injection unit. 3. When the desired position is reached, secure the grubscrew with the lock nut. 4. Re-tighten the 6 socket head cap screws under the injection unit mounts.

To move the injection unit towards the non-operator side: 1. Release the four socket head cap screws under the front injection unit mount. 2. Release the two socket head cap screws under the rear injection unit mount. 3. Release the locknut and grubscrew and unscrew the grubscrew 2 or 3 turns. 4. On the operator side front mount, use a pry bar (at the lever point) to move the injection unit towards the non-operator side.

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149

MAINTENANCE: 5. 6. 7.

When the desired position is reached, screw in the grub-screw without applying pressure and lock into place. Re-tighten the 6 socket head cap screws under the injection unit mounts. Feed and inject the screw several times and re-check the injection unit level.

The centering procedure may cause the injection unit to yaw (move to the side), if the injection unit is yawing, adjust as follows: 1. Run the nozzle to within 1/2" of the mechanical stop. 2. Remove the “Detent pin” and “Shoulder pin” from the coupling rod on the operator side. 3. Run the nozzle to the mechanical stop. 4. Loosen the “lock nuts” on the carriage cylinder coupling rod. 5. Turn the “Adjustment nut” until the hole in the Joint is aligned with the hole in the “Coupling” Rod mounts. 6. Insert the “Shoulder Pin’ and secure with the “Detent Pin”. 7. Secure the “Connecting Rod” with the lock nuts.

LOCKNUTS INJECTION UNIT SIDE

CLAMP SIDE

ADJUSTMENT

150

4. INSTALLATION

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MAINTENANCE: 14.2 SWIVELLING THE INJECTION UNIT.

LEVER POINT TO MOVE UNIT

1. 2. 3. 4. 5. 6.

CAM ADJUSTER ECCENTRIC CAM ADJUSTER

ALLEN SCREW CLAMP

FRONT INJECTION UNIT MOUNT LOCKING HANDLE

REAR INJECTION UNIT MOUNT

Clamp the front part of the Injection carriage to the linear bearings. Remove the four socket head cap screws under the front "injection unit mount". Loosen the two socket head screws under the rear "injection unit mount", but do not remove. Disconnect the coupling rods at the stationary platen. Remove the detent pins and pull the coupling rod shoulder pin up and out to release the coupling rods. Pull the injection unit to the operator side.

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4. INSTALLATION

151

MAINTENANCE: 15.

SWIVELLING THE INJECTION UNIT - IN-LINE INJECTION UNITS.

1.

Switch the machine off and lock out the electrical power to the machine using an approved lockout procedure that is in force at the customer’s facility. 2. Discharge or lock out any residual hydraulic pressure, such as accumulators. 3. Allow the plasticizing barrel time to cool down. 4. Disconnect the coupling rods at the stationary platen. • Remove the detent pins and pull the coupling rod shoulder pin up and out to release the coupling rods.

5. 6. 7. 8.

152

Push the injection unit fully back. Raise the purge shield. Remove the lock screw as shown in the diagram and figures overleaf. Pull the injection unit to the operator side.

4. INSTALLATION

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MAINTENANCE:

Operator side of injection unit Remove the socket head cap screw, indicated by the arrows, to enable the injection unit to be swivelled.

Operator side of injection unit

Injection unit swivel stop - non operator side When returning the injection unit to the normal operating position, push the unit back against the “swivel stop” and secure the bolt that prevents swivelling.

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4. INSTALLATION

153

MAINTENANCE: 16.

ADJUSTING NOZZLE HEIGHT - VERTICAL ROTARY BRIDGE MACHINES

16.1 TO RAISE AND LOWER THE HORIZONTAL INJECTION UNIT. The height adjustment is located at the rear of the machine. The adjustment is locked against accidental movement, by a safety pin. To enable the injection table height to be adjusted pull the safety pin out by the ring. Using an appropriate sized socket and ratchet or pneumatic nut driver, adjust the height of the injection unit as required. The table is raised or lowered on three interconnected jacks. Adjust the height of the table so that the nozzle co-incides the sprue bushing on the mold. To relocate the safety pin, turn the height adjustment until the hole in the shaft lines up with the “locking bracket” and re-insert the pin to prevent further movement.

Height Adjustment

Locking bracket

Safety pin

Safety pin removed

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4. INSTALLATION

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MAINTENANCE: A bar is attached to the injection unit, to limit the movement of the table. A scale is provided to give a an approximate position of the table, relative to the end positions. The pointer for the scale is attached to the stop bar.

Movement limitation bar Height adjustment

Height indication pointer

Height scale

Rear view of the Vertical clamp, rotary table injection molding machine.

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4. INSTALLATION

155

MAINTENANCE: 17.

SCREW TIP REPLACEMENT • Prepare the new screw tip as shown

Screw Tip

NOTE!

Use Anti-Seize on threads

Refer to section 4.11 of this Chapter for the correct antiseize compound to use when re-assembling Engel injection molding machine components.

• Loosen front heater band and remove barrel head. • Loosen socket screws on locking ring at the rear of the screw, turn locking ring clockwise to unlock splines. • Pull the screw from the barrel, to expose the screw tip. Turn the screw tip counterclockwise to unscrew.

• Fit new screw tip and turn clockwise to tighten.

• • • •

156

Push screw tip back into barrel. Replace barrel head, but do not tighten bolts. Tighten front heater band (failure to do so will cause heater band to burnout). Heat up screw tip in barrel.

4. INSTALLATION

16/12/05

MAINTENANCE:

• When the barrel has reached the correct working temperature. • Loosen front heater band.

• • • • • •

16/12/05

Remove barrel head. Pull out screw and tighten screw tip Push screw back into barrel, aligning the splines on the ends of the screw with the splines in the injection ram. Turn the locking ring anti clockwise to lock the screw to the ram and tighten the three screws on the locking ring (See Table 4.1). Fit the barrel head and nozzle and tighten the barrel head bolts (See Table 4.1). Tighten all heater bands

4. INSTALLATION

157

MAINTENANCE: 18.

TORQUE SPECIFICATIONS

18.1 CAP SCREWS This information covers metric plain (not coated) standard coarse thread fasteners for general applications. The values given must not be exceeded without authorization from ENGEL.

NOTE! 1. Refer to section 19 in this chapter for information concerning the correct anti-seize compound to be used in the re-assembly of machine components 2. Consult manufacturers specifications to verify performance of coated or plated screws for any critical applications. All socket head cap screws used by ENGEL CANADA of grades 12.9 or 10.9 are tightened to the torque values specified for grade 10.9, unless the application or drawing specifies otherwise. It is desirable but not mandatory that all screws be of the same grade in a given assembly. Where grade 12.9 screws are specified, grade 12.9 torque values must be applied. It is then mandatory that all screws used must be grade 12.9. The socket head cap screw applications are broken down into group usage in the table below. The torque settings for each group are detailed in the tables overleaf. The torque settings, in the tables, are specified in both the SI (metric) and Imperial systems of measurement. Group 1

Hydraulic cylinders

Group 2

Plasticizing cylinders and Barrel Heads

Group 3

Components on the clamp unit that fasten parts which experience: Clamping force Opening force

Group 4

Components on the injection unit that fasten parts which experience: Injection force Retraction force Contact force Plasticizing screw torque

Group 5

Safety Gates and moving guard critical parts. Secure screws with Loctite 242, (Torque specifications are not mandatory for these parts)

Group 6

Hydraulic Valves and Manifolds

Group 7

Pump - Motor assemblies

158

4. INSTALLATION

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MAINTENANCE: Table 4.1 Recommended Cap Screw Torque Settings DIN 912 - Metric Plain Socket Head Cap screws (not coated) Groups 1, 3, 4, 6 & 7 (Standard Coarse Thread)

SIZE M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48

TORQUE Nm Grade 10.9 8 13.4 33 64 113 275 543 918 1878 3215 5235 7198

TORQUE ft-lbs Grade 10.9 6 10 24 48 84 203 400 677 1386 2370 3860 5270

DIN 912 - Metric Plain Socket Head Cap Screws (not coated) with anti-seize compound applied. Group 2 Barrel Heads (Standard coarse thread)

SIZE M10 M12 M16 M20 M24 M30 M36

TORQUE Nm Grade 10.9 47 80 200 392 672 1360 1920

TORQUE ft-lbs Grade 10.9 35 59 148 290 496 1004 1417

NOTE! The elevated working temperature reduces the yield strength of the screw material. To compensate for this fact, the table above reflects a 20% reduction from the standard torque values ( anti-seize co-efficient of friction = 0.10). These values are to be used for hot or cold applications, but all the components must all be at the same temperature (i.e. the barrel, barrel head and screws).

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4. INSTALLATION

159

MAINTENANCE: DIN 933 Metric Plain Hexagon head screws (uncoated) Standard course thread. The table below reflects the torque setting for the general purpose hexagon head screws used on the injection molding machine.

SIZE M5 M6 M8 M10 M12 M16 M20 M24 M30

Grade 8.8 Torque Nm Torque ft-lbs 5.5 4 9.5 7 23 17 47.4 35 77.4 57 195 144 390 288 669 494 1350 996

Grade of Screw - The grade number is marked on the head of the screw, the number before the point refers to the maximum tensile strength in kilograms times 10 per mm2 and the number after the point refers to the percentage yield of the screw. Size of Screw

- The size is marked on the head of the screw, M refers to METRIC and the number refers to the diameter across the shank in millimetres.

Torque

- The torque is the tightening force applied to the screw in pounds force per foot (lbf ft.) or Newton metres (Nm).

18.2 MOLD MOUNTING BOLTS - U.N.C. The torque specifications for the bolts given in the table below are average values based on the following parameters: • Uncoated (plain steel). • Hexagon head, U.N.C. • ASTM A307 grade A. • Dry application, i.e. no lubrication on the threads or head of the bolt. Shank diameter (Inches) Bolt grade

5/8

3/4

1

1 1/4

SAE

Low carbon steel

2

107

185

373

675

Medium carbon steel

5

157

252

647

1105

Heat treated

8

215

356

807

1211

lbf -ft torque

The values are just guidelines, please consult an Engineer’s handbook for more information on the different grades of U.N.C. bolts. U.N.C. bolts have markings on their heads that indicates the grade. If the mold mounting holes, in the platens, have metric threads, please use the table for hexagon head metric bolts given above.

160

4. INSTALLATION

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MAINTENANCE: 19.

ANTI-SEIZE COMPOUND

There will be two types of anti-seize compound that are used on Engel machines: 1. Anti-Seize C5-A from Fel-Pro This copper and graphite anti-seize should be used exclusively. Exception: Dissimilar metals (see Heavy Duty Anti-Seize) Example of C5-A anti-seize use: a.

Plasticizing cylinder and injection unit

All engaged screw threads and locating diameters on the: • Plasticizing screw tip • Barrel head fastening screws and locating diameter • Nozzle body • Nozzle tip • Locating diameter on the back end of the barrel • Split ring and groove where applicable • Quick barrel change grooves where applicable • Feed throat screw fasteners. b. • • • • •

c.

Injection Screw spline Injection cylinder flange locating diameter Screw drive motor shaft and locating diameter Adapter for screw drive motor shaft Injection swivel plate (test to be made with Moly Paste and EP grease)

Pump motor assembly • Pump motor shaft, coupling and key • Locating diameters

d.

2.

Clamp assembly • Tie rod ends and nuts at stationary platen end • Locating diameters of hydraulic cylinders, ejector and clamp • Quick mold clamp cam bushing “Heavy Duty Anti-Seize” from Fel-Pro

This graphite and calcium fluoride anti-seize is to be used for application of dissimilar metals. Example of Heavy Duty Anti-Seize usage: • Stainless steel / steel components • Casting / steel components • Aluminum / steel components

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4. INSTALLATION

161

MAINTENANCE: 20.

INSTALLATION OF HEATER BANDS

To install, slide the heater band over the barrel and align the thermocouple mounting hole in the barrel with the thermocouple hole in the band. Tighten the heater band firmly, bring the barrel up to operating temperature and re-tighten the bands. Allow the barrel to cool and re-tighten the heater bands again. This procedure is only performed when installing new heater bands to take up any initial stretch that may be in the units.

THERMOCOUPLE

HEATER BAND

162

4. INSTALLATION

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MAINTENANCE: 5. START UP AND SHUT DOWN PROCEDURE 1.

STARTING PROCEDURE

The following instructions assume that all necessary connections have been made to allow the machine to operate correctly. All breakers must be in the ON position and all water hoses must be properly connected. At the machine control panel (See Figure 5.1); Step 1: Turn the CONTROL VOLTAGE switch to ON.T here is a control voltage switch on the EC88 and CC90 machines. To release the emergency stop button, simply turn it to the right until it springs out. Step 2: Turn on the cooling water supply. Ensure that both the water supply inlet and the water supply outlet have been properly connected to allow for cooling water flow (i.e. heat exchanger, feed throat, platens, mold, etc.) Step 3: Turn the HEAT SELECTOR switch to AUTO. The correct operating temperature for the screw and barrel will be reached in approximately 15 to 20 minutes. Step 4: Reset the controls by the MODE SELECT switch (program interruption button "PU") from MANUAL to AUTOMATIC and back to MANUAL. The motor will start only when this switch is in the manual position and the rear gate is closed. Step 5: Operate the MOTOR switch to START and release. This will start the electric motor which drives the pump system. Step 6: Monitor the hydraulic oil temperature and the barrel temperatures.

NOTE! As soon as you receive the machine, take note of the normal state of all LEDs within the electronic cabinet. • • • • •

Digital input cards. Digital output cards. E-7 Analog card. E-7 Temperature cards. PS88 power supply card.

Record the normal state of these LEDs, either ON or OFF, this will more closely pinpoint the problem area and enable a quicker solution to be arrived at if minor electronic faults are encountered.

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163

MAINTENANCE:

MOTOR OVERLOAD

CORES & EJECTORS ACTIVATION

ALARM BELL SILENCE

SAFETY GATE OPEN CLOSE

MOLD WIPER OUT IN

MOLD GATE CLOSE OPEN

EJECTOR BACK FORWARD

CORE OUT IN

AIR BLOW ON

MOLD CLAMPING PART CHUTE CLAMP AUTO CLOSE SECURERELEASE OPEN REJECT STORE

MODE SELECT MANUALAUTO

CYCLE START

MOLDHEIGHT INCR. DECR.

CORES & EJECTORS NO MOTIONMOTION

NOZZLE FORWARDBACK

INJECTION INJECT FEED

HEAT CONTROL VOLTAGE OFF AUTO OFF ON

MOTOR STOP START

EMERGENCY STOP

A7601222

Figure 5.1 Typical Control Panel.

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5. START UP AND SHUT DOWN PROCEDURE

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MAINTENANCE: 2.

MACHINE SHUT-DOWN.

The following general shut-down procedures apply when molding with common plastic materials such as polyethylene (PE), polypropylene (PP), polystyrene (PS), etc. Step 1: Slide the raw material hopper back and away from the feed throat so that no further material drops through to the plasticizing screw. Step 2: Switch the HEAT switch to the OFF position. Step 3: Engage the manual or semi-automatic mode of operation. Step 4: Move the carriage unit back and away from the carriage forward position. Step 5: Reduce injection pressures and "purge" out the barrel by injecting and screw feeding until most of the material has been removed from the barrel. Clear away and dispose of the contaminated purged material. Step 6: Examine the mold cavity and clean if necessary. Afterwards, close the mold until the two mold halves are just touching but no clamp force is being applied. This keeps the mold cavities contamination free during the shutdown period. Step 7: Switch the CONTROL VOLTAGE switch to OFF. Step 8: Switch off the main breaker on the power-supply cabinet. Step 9: Turn off the cooling water supply.

NOTE! 1. If there is any possibility of the temperature falling below freezing make sure that all water has been removed from mold cavities, heat exchangers, water towers, etc. 2. If the machine is equipped with an accumulator, make sure that the accumulator has been relieved of any pressure. Monitor the manual gauge to ensure that this important step has been carried out.

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165

MAINTENANCE: 3.

MANUAL TO AUTOMATIC CYCLE

The following instructions assume that: The oil temperature is within the set operating range, The barrel temperatures are within their specific tolerances, That all safety devices have been checked and verified by the maintenance department as being fully operational and correctly adjusted. Step 1: With the MODE SELECT switch in MANUAL, ensure that: • The mold is at position "A". • The ejector is at position "L". • The screw is at position "C1" (and "C2" if decompression before or after screw refill used). Step 2: Switch the selector switch on the push-button panel to automatic Step 3: Press the automatic mode button on the control unit (or semiautomatic). Step 4: Open and close the front safety gate.

4.

CORES AND EJECTORS SWITCH.

If the CORES and EJECTORS switch is turned to MOTION and the machine is in semi-automatic, the operator will be able to open the front gate while the mold opens. The ejector will also move forward and the cores will be allowed to move out.

166

5. START UP AND SHUT DOWN PROCEDURE

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MAINTENANCE: 6. HYDRAULIC SYSTEM 1.

BASICS OF HYDRAULICS

The question "What is hydraulics ?" can be answered in the following way. Hydraulics is the transmission and control of forces and motions through the medium of fluids. Hydraulic systems and equipment have wide-spread application throughout industry. For example: • - machine tool manufacturing • - press manufacturing • - plant construction • - vehicle manufacturing • - aircraft manufacturing • - shipbuilding • - injection molding machines Prerequisites that hydraulics requires of the user and serviceman: • - knowledge of the basic physical laws of hydrostatics and hydrodynamics • - knowledge of the symbols of hydraulic control elements • - knowledge of hydraulic circuit diagrams • - knowledge of the maintenance of a hydraulic system Hydraulic to Electrical Analogy Hydraulics and electrics are analogous, because they both deal with flow, pressure and load. The components in each type of circuit perform similar functions and therefore can be related, a few examples are listed below: Hydraulic Pump Hydraulic Motor Directional Control Valve Hoses Cylinder Check Valve Relief Valve Accumulator Booster

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←→ ←→ ←→ ←→ ←→ ←→ ←→ ←→ ←→

6. HYDRAULIC SYSTEM

Generator Electric Motor Switches Wire Solenoid Diode Circuit Breaker Capacitor Transformer

167

MAINTENANCE: 1.1

CONVERSION OF ENERGY IN HYDRAULICS

Drive Electric Motor

Electric Energy

hyd. pump

Mechanical Energy

hydraulic control and regulating units

Hydraulic Energy

User hyd. cylinder hyd. motor

Hydraulic Energy

operating element to be actuated

Mechanical Energy

Various forms of energy are converted to accomplish mechanical movement in the injection molding machine. Electrical energy is converted to mechanical energy, which in turn is converted to hydraulic energy to operate and control the moving components of the machine. The hydraulic energy is converted to mechanical energy to achieve the final desired result, which may be "mold clamping pressure" or "material injection". The figure above summarizes the energy conversions for an injection molding machine.

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6. HYDRAULIC SYSTEM

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MAINTENANCE: Pascal's Law Pascal's Law states that a pressure acting on a confined fluid is transmitted equally and undiminished in all directions. In the figure below, a 10 pound force acting on a 1 square inch area generates a pressure of 10 pounds per square inch (psi) throughout the container acting equally on all surfaces.

10 pounds force

over 1 sq. in.

10 p.s.i.

This principle is important to remember, that the pressure in any portion of an hydraulic system is equal throughout that system. This statement is valid with the omission of the force of gravity, which would have to be added, according to the fluid level. Due to the pressures that hydraulic systems operate at, this smaller amount need not be considered e.g. a 32 foot head of water approximately equals 14.5 psi. (a 10 metre head of water approximately equals 1 bar.)

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169

MAINTENANCE: Force Transmission in Hydraulics One of the main advantages on the use of hydraulic to power our molding machinery is the efficient transmission of forces. If force F1 is exerted on surface A1, pressure p is created. (p = F1). A1 Since pressure affects all parts of the system equally, therefore pressure p is applied to surface area A2. Force F2 will equal pressure p x surface area A2 (F2 = p x A2), and transposing that formula for p = F2 A2. Since p = F1 therefore F2 = F1 A1 A2 A1. In the diagram below, the following relationships hold:

Where

S= A= F=

=

A2 A1

=

F2 F1

piston stroke piston area force

F1

A1

S1 S2

F2

S2

S1

A2

If A1 = 1 square inch and A2 = 10 square inches, then a force of F1 = 10 pounds can support a force of F2 = 100 pounds. However, the strokes of the pistons are inversely proportional to their surface areas . If the smaller piston were moved in the direction of S1 by 10 inches, then the larger piston will only move 1 inch in the direction of S2.

170

6. HYDRAULIC SYSTEM

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MAINTENANCE: Area and Force As the clamp piston is moved forward during the clamp close function, the pressure developed acts upon the clamping piston which has a certain size or area.

P x A =F

S1

S2

M

A6411650 A basic formula in hydraulics states that pressure multiplied by area to which that pressure is applied equals force. i.e. pressure x area = force p

x

A =

F

The formula can be manipulated to calculate any one of the three variables p, A or F, if any of the other two variables are known. As follows: pxA=F F/p=A F/A=p

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171

MAINTENANCE: Pressure Hydraulic pressure is generated when a flowing fluid meets resistance which is generally related to the load that is being moved.

Load

A6411649

Hydraulic Pressure

A force is applied via the lever to produce system pressure (p = F/A or F = p x A). If more force is applied, the system pressure rises until the load moves, if the load remains constant the pressure will increase no further. The load can therefore be moved if the necessary pressure is generated. The speed at which the load moves will be dependent upon the volume of fluid which is fed to the load cylinder. For example, as the mold is opening or closing, the pressure generated in the system represents the resistance of the toggle lever to movement. Adding to that resistance would be the weight (i.e. mass) of the mold and toggle lever and also the friction between the toggle lever bushings and the tiebars. When the two mold halves touch and the toggle begins to straighten out, the increasing pressure represents that which is required to stretch the tiebars in the generation of a particular clamp force. Similarly when injecting material into the mold the pressure generated in the injection system represents the resistance of the injection ram to movement. Adding to that resistance would be the mass of the injection ram and screw, the friction between all moving components and the resistance of the plastic melt as it is forced quickly into the mold cavity.

172

6. HYDRAULIC SYSTEM

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MAINTENANCE: Pressure Control In order to safeguard the system, pressure relief valves are installed. The valves serve to limit the amount of pressure that can develop in the hydraulic system since the various hydraulic components are expensive and they are subject to pressure limitations before failure occurs. One characteristic of fluid flow that is important to note here is that flow occurs always in the path of least resistance. Pressure would continue to rise in the circuit consistent with the load being moved. The pressure relief valve is always set to allow flow to travel through the relief valve well before pressure rises above safe levels and causes damage to the system and its components. In other words, the path of least resistance is employed here to safeguard the system after the other movements have taken place.

A 100 LBS

B 50 LBS

C 10 LBS

A6411653

1500 psi Pressure Relief Valve M

• • •

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Load "C" would move first, because it is the lightest. Load "B" would move next, because it is the second lightest. Load "A" would move last, because it is the heaviest.

6. HYDRAULIC SYSTEM

173

MAINTENANCE: Pressure Override An extremely important concept to understand about pressure relief valves is their pressure override characteristics. Pressure override is the difference between the pressure at which the relief valve just starts to crack open and the pressure at the full open position. For direct acting pressure relief valves this pressure differential can be as high as 30% and proportional pressure relief valves range from 10% - 20%.

Full Flow Pressure Cracking Pressure Pressure Override

Ideal Pressure Setting

During injection, "P6, Injection Boost Pressure Limit", must be set high enough to recognize this inherent feature of the pressure relief system. This is extremely important for open loop systems since a "P6" setting that is too low will adversely affect speed control during injection. Although pressure override is not a factor on Moog valve equipped machines, setting "P6" to a level less than the minimum required to inject the plastic will also affect closed loop speed control.

174

6. HYDRAULIC SYSTEM

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MAINTENANCE: Pressure Intensification

Another important concept to keep in mind is that of pressure intensification. This law of hydraulics is often forgotten when troubleshooting hydraulic circuits.

A1

P1

A2

F1

P2

A6411655

For example, if two pistons of different size are connected by a rod, the pressure existing on the smaller area will always be greater. This principle also applies to the cap side and the rod side of a normal double acting piston. If P1 = 1,000 psi and A1 = 10 square inches, then F1 = 10,000 pounds of force. If F1 = 10,000 pounds of force and if A2 = 5 square inches, then P2 = 2,000 psi.

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6. HYDRAULIC SYSTEM

175

MAINTENANCE: Speed in Hydraulics

The speed of a hydraulic component can be calculated based on the formula below:

S= V/t A Where, S = piston speed V / t = volume of oil over time (i.e. gpm) A = piston area For example, given the conditions below the injection piston, therefore the screw, will move at 3.85 inches per second. However, this speed will not be possible if the pressure relief valve opens. (See Pressure Override)

10 INCHES SQUARE AREA

S=

10 GPM __________

(1 gallon = 231 cu. in.)

10 in. sq.

S=

2310 cu.in./min ____________

10 GPM

1500 PSI

10 in. sq. S = 231 in./min or 3.85 in/sec.

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6. HYDRAULIC SYSTEM

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MAINTENANCE: Hydrodynamics

As well as understanding the concept of speed in hydraulics, it is also important to have some insight into flow characteristics. For example, the drawing below shows that when oil is flowing through different diameter pipes an equal volume flows in an equal unit of time. If that is true and if the shaded quantity Q1 equals the shaded quantity Q2, then velocity V2 must be greater than velocity V1.

Q2

Q1 V2 V1

As the diameter of the pipe decreases, the flow rate will increase. Specifically, if the pipe diameter decreases by one half in the direction of oil flow, the cross sectional area will decrease by four times, and visa versa. Oil flow velocity through different pipe sizes can be calculated using the formula: Velocity (feet per second) = GPM / 3.117 x area

2 inch diameter

1 inch diameter

A6411657

The same gallons per minute will have to travel 4 times faster through the smaller pipe.

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177

MAINTENANCE: Another important concept in hydrodynamics is how fluids flow based on certain critical flow speeds or as the result of meeting restrictions to flow such as bends in the pipe or system components.

LAMINAR FLOW

One goal in the initial design of hydraulic power transmission systems is to encourage laminar flow as much as possible since an increase in turbulence will increase flow resistance and hydraulic losses as well. The diagram below illustrates the concept of turbulent flow.

TURBULENT FLOW

Although turbulent flow is wasteful in most hydraulic applications, it is desirable to have turbulence in the oil flow as it travels through the heat exchanger for cooling purposes. If turbulence exists as the oil flows through the heat exchanger, more of the oil molecules come into contact with the heat exchanger cooling tubes and more efficient cooling is the result.

178

6. HYDRAULIC SYSTEM

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MAINTENANCE: 1.2

DIRECTIONAL CONTROL

One of the main advantages of hydraulic based systems is that the oil flow direction is easily controlled. The drawing below shows a piston being extended, held stationary and then retracted, simply by changing the position of a directional valve. Even though the drawing is simple in nature, it still demonstrates the principle involved in directional control. In addition to simple directional control valves, we also employ proportional directional control valves on some machines to control the clamp opening and closing function.

EXTEND

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HOLD

6. HYDRAULIC SYSTEM

RETRACT

179

MAINTENANCE: Hydraulics in Action

The next few pages show a simple hydraulic system in action.

4.2

Atmospheric pressure acts down on the oil in the oil tank (2) forcing the hydraulic oil to the pump inlet (1). Oil is pumped towards the directional control valve (5) through the pressure line (P). The pressure in the system is what ever it takes to move the load.

4.1

LOAD

The position of the directional control valve spool (6) allows the oil to be pushed towards the cap end of the piston (4.1) through the working port (A). The load is connected directly to the piston rod and will extend with the piston. The rod side oil is forced back to the oil tank via working port (B) of the directional control valve and the tank line (T).

5

6 T

B

A

P 1

2

180

6. HYDRAULIC SYSTEM

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MAINTENANCE: In any hydraulic system, pressure must be allowed to increase to a level sufficient to move the load.

4.2

4.1

In all cases however, there must also be a limit to that pressure in order to protect the system and its components (seals, hoses, etc.). To provide a protective limit against a damaging pressure rise, a pressure relief valve (3) must be provided. When system pressure increases to the pressure relief valve setting, the valve would open and the pump flow would travel back to the tank (2) through tank line (T).

LOAD

5

6 T

B

A

P

1

2

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6. HYDRAULIC SYSTEM

181

MAINTENANCE:

4.2

Atmospheric pressure acts down on the oil in the oil tank (2) forcing hydraulic oil to the pump inlet (1). Oil is pumped towards the directional control valve (5) through the pressure line (P). The pressure in the system is what ever it takes to move the load.

4.1

LOAD

The position of the directional control valve spool (6) allows oil to be pushed towards the rod side of the piston (4.2) through working port (B). The load is connected directly to the piston rod and will retract with the piston. The cap end oil is forced back to the oil tank via working port (A) of the directional valve and the oil tank line (T).

5

6

T

B

A

P 1 2

182

6. HYDRAULIC SYSTEM

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MAINTENANCE:

4.2

There are various valves that can be installed to control the speed of any particular hydraulic system. The drawing shows an in-line, manually adjusted flow control valve (7) placed in the system to control the speed of the load. Notice that the speed would be controlled in either the extension or retraction modes.

4.1

LOAD

Since the pump shown is a fixed displacement model, a continuous and constant volume of oil is output to the system. If the flow control valve is adjusted to slow down the load, the excess flow would go over the pressure relief valve at the pressure relief setting.

5

6

T

B

There would be two pressures in this system. The relief valve pressure existing between the pump (1) and the flow control valve (7) and the load pressure existing between the flow control valve and the load.

A

P 1 2

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6. HYDRAULIC SYSTEM

183

MAINTENANCE: 2.

INJECTION MOLDING MACHINE HYDRAULIC SYSTEM

ELECTRIC MOTOR

PUMP

PRESSURE & VELOCITY CONTROL VALVES

DIRECTIONAL CONTROL VALVE

VELOCITY CONTROL

CLAMP CYLINDER

SERVO CONTROL

CARRIAGE CYLINDER

HYDRO MOTOR

COREPULL CYLINDER

INJECTION CYLINDER

SCREW

184

6. HYDRAULIC SYSTEM

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MAINTENANCE: 3.

HYDRAULIC SYSTEM OVERVIEW.

The Injection Molding Machine uses an hydraulic system to produce high clamping pressures that are required in the production of thermoplastic moldings and also to efficiently transmit and control the motive power of the machine. The hydraulic pump, driven by an induction motor, produces the flow of hydraulic oil to drive: • The Hydromotor which turns the plasticizing screw that delivers the molten plastic to the end of the injection cylinder. • The Injection Cylinder backwards and forwards to expel the molten plastic into the mold and withdraw for the next charge. • The Injection Carriage backwards and forwards to deliver the tip of the barrel to the mold • The Clamp Cylinder to open and closed the mold. • The Ejector Corepulls to release the molding from the mold. The following major components which are described in this chapter: 8. Variable displacement pump. 9. Hydromotor. 10. Injection Cylinder. 11. Carriage Cylinder. 12. Clamp Cylinder. 13. Ejector Corepull Cylinders. Variable Displacement Pump.

The Variable Displacement Pump operations are discussed in paragraph 6.9 of this chapter. Hydromotor (Hydraulic motors).

The Hydromotor operation is discussed in section 5 of this chapter. Injection Cylinder.

The Injection Cylinder is of a double acting type providing sufficient force for high injection pressure speed as well as position suckback for melt decompression to prevent drooling of the material. the hydraulic force is transmitted over the floating screw drive onto the screw generating injection pressure. The Injection Cylinder extension circuit employs a regenerative system for faster injection speeds.

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6. HYDRAULIC SYSTEM

185

MAINTENANCE: Regenerative Circuit

Some Engel machines make use of a regenerative circuit for a faster injection speed. A regenerative type circuit is a trade off between injection pressure and injection speed. If one increases, the other decreases in a proportional manner. The regenerative effect works by combining the oil flow being expelled from a cylinder, as it extends, with the pump flow, which will extend the cylinder faster. In reality, more gallons per minute (GPM) are being pumped into the cylinder than would otherwise be the case without the regenerative set-up. The diagram below shows a circuit with a regenerative capability. When solenoid S4D is switched, the oil flow from the rod side of the cylinder is added to the pump flow, which results in more GPM extending the cylinder. Since more gallons per minute are extending the cylinder, obviously the cylinder moves faster. Assume that the machine is set to run at 3 inches per second. If the injection pressure is increased, the injection speed would decrease unless corrective action is taken. In this case, to have the increased injection pressure and still have the machine run at 3 inches per second, the fluid flow rate to the injection cylinder must be increased. This adjustment is done automatically in the microprocessor based control system of the machine.

INJECTION

S4D

TANK

186

FROM PUMP

6. HYDRAULIC SYSTEM

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MAINTENANCE: Non - Regenerative versus Regenerative Non - Regenerative

2000 lbs. FORCE

ROD SIDE = 1 INCH SQUARE BLIND SIDE = 2 INCHES SQUARE PRESSURE = 1000 PSI 5 GPM

10 GPM TANK

FROM PUMP

Force = System pressure x Area

Speed = Flow / Area

Force = Lbs/ Inches2 x Inches2

Speed = Inches3 per minute / Inches2

Force = 1000 x 2

Speed = 10 x 231 / 2

Force = 2000 lbs

Speed = 1155 inches / minute

In a non-regenerative system, oil is delivered to one side of the piston to extend or retract it and oil from the other side is expelled to tank, which is at zero system pressure. The figure above shows a simple hydraulic circuit with values for: • System pressure, • Flow rate, • Cross sectional areas. Force and speed for any similar arrangement can easily be calculated from the formulae given above.

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6. HYDRAULIC SYSTEM

187

MAINTENANCE: Regenerative

1000 lbs. FORCE

2000 lbs. FORCE 1000 lbs. NET FORCE

ROD SIDE = 1 INCH SQUARE BLIND SIDE = 2 INCHES SQUARE PRESSURE = 1000 PSI 5 GPM

10 GPM TANK

FROM PUMP

Force = System pressure x Area

Speed = Flow / Area

Force = Lbs/ Inches2 x Inches2

Speed = Inches3 per minute / Inches2

Gross Force = 1000 x 2

Speed = 10 x 231 / 1 inches per minute

Gross Force = 2000 lbs

Speed = 2310 inches / minute

Net Force = 1000 x 1

Speed (Regen) = 2 x Speed (non regen)

Net Force = 1000 lbs The oil flow from the rod side of the cylinder combines with the flow from the pump. The pump only has to make up the volume difference between the blind side and rod side. Consequently the pump only has to supply the volume of oil equivalent to the rod side. Supplying a flow of 10 Gallons per minute, as the diagram shows, results in a doubling of the speed. The opposing force from the rod side of the cylinder detracts from the force on the blind area, resulting in a net force half that of the non regenerative system. During regeneration equal pressure is applied to both sides of the cylinder piston. The net force delivered by the rod will be the same as if the effective pressure were applied only to an area equal to the rod, but on the blind side of the piston. Regeneration is employed in clamp closing circuits until the mold halves touch and is operator selectable for injection. When the full force is required the hydraulic circuit is switched back from the regenerative mode to the non-regenerative mode.

188

6. HYDRAULIC SYSTEM

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MAINTENANCE: The figure below shows a typical hydraulic circuit diagram. A regenerative circuit is employed to increase the injection speed.

INJECTION CYLINDER HYDROMOTOR J

S4D

A

B

P

T

Y3

B

a P

A

T

A

B

P

T

A

B

S3 P SCREW TURN

T

a IREGEN. INJECTION

a

S24 SUCKBACK

Figure 6.2 Injection Cylinder Regenerative Circuit Flow.

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6. HYDRAULIC SYSTEM

189

MAINTENANCE: Carriage Cylinder.

The two carriage cylinders mounted on the injection unit provide the necessary nozzle force and travel. The figure shows the control valve arrangement and solenoids that control the backwards and forwards movement of the carriage cylinders.

CARRIAGE CYLINDER

G1

B

A S6

S5 FWD

BACK P

T

Figure 6.3 Carriage Cylinder.

190

6. HYDRAULIC SYSTEM

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MAINTENANCE: Ejector Corepull.

The Ejector provides enough force to eject the moldings from the mold. The Corepull activates mold components around which the plastic is molded. The figure shows the control valve arrangement and solenoids that control the forward and retract movement of the ejector and corepull circuits.

EJECTOR

A6

B6

RETRACT

S26

COREPULL1

FWD

A

B

P

T

A5

CORE OUT

S25

H

B5

S14

CORE IN

A

B

P

T

F

S15

H

F

PRESSURE TANK

Figure 6.4 Ejector Corepull.

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6. HYDRAULIC SYSTEM

191

MAINTENANCE: Clamp Cylinder.

The clamp cylinder provides the necessary force for opening and clamping the mold. The advantages of a hydraulic clamp are that the system is infinitely variable and the clamp forces and speed can be controlled and changed at any time, to provide high speed to close the mold and low speed and high pressure to clamp up the mold. The hydraulic clamp offers smooth acceleration because of the fluid nature of the system and as a consequence the fluid continually lubricates the components resulting in a minimum maintenance requirement. Hydraulic Versus. Toggle Clamping Force in a hydraulic system is calculated by the mathematical equation below: Force = Pressure (PSI) X Area (sq. ins.) The area required to produce a given force can be calculated with the equation:

Area

=

Force -------Pressure

Therefore, in a strictly hydraulic system, to produce 400 tons of compressive force at a system pressures of 160 bar (2320 psi) a clamp cylinder of the size calculated below will be needed:

Area

=

800,000 lbs. -----------= 2320

345 inches squared

This equates to a clamp cylinder diameter size of 21 inches! This size cylinder would require huge pumps to supply the quantity of fluid necessary to move the cylinder at our cycle times. These high compressive forces have to be produced by other methods than strictly hydraulic force. Larger Engel machines use a double folding toggle mechanism to achieve these high forces.

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MAINTENANCE: Toggle mechanisms are often used when a large force moving through a small distance is required. For example, consider the drawings below. FIXED PLATENS

FIXED PLATENS

CLAMP CYLINDER

Í

A6410114 ED91.641.7777E.P1

MOVING PLATEN

MOVING PLATEN

What would happen between the fixed and moving platens in the right hand drawing if the clamp cylinder was extended any further? Take note of the fact that the platens are touching. The forces acting horizontally would increase dramatically (approaching infinity) as the linkage straightens out. When the toggle does straighten out, the forces acting horizontally actually stretch the four tie bars holding the platens together. In other words, the tie bars really act as huge springs. The more the tie bars are forced to stretch, the higher is the compressive force applied between the moving and fixed platens. Safety Gate Hydraulic Interlock.

The Injection Molding Machine has an operator side and a non operator side safety gate (see Chapter 3) which when slid back, activate an hydraulic interlock. The interlock is a directional control valve and with the safety gates closed allows oil to the clamp cylinder, but when the gates are opened the valve is extended and vents the "extend" side of the clamp cylinder to tank thereby preventing the clamp from closing. CLAMP CYLINDER SAFETY GATE-FRONT

A

A

B BE8

P

T

T

P

RETRACT

EXTEND

TANK

Figure 6.5 Hydraulic Interlock.

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MAINTENANCE: Table 6.1 Sheet 1 of 6 Hydraulic Symbols

Working line, tank or return line. Generally, the heavier solid lines indicate pressure (P) and the lighter solid lines indicate the tank (T) return lines. In general, the heavier dashed line indicates a pilot line and the lighter dashed line indicates a drain line to tank, labelled (L)

Indicates a flexible line (i.e. a hose)

Indicates a line junction

Indicates crossing, but not connected lines.

Indicates a manifold for several components which are assembled as one unit. For example, a number of cartridge valves controlled by various directional control valves. Tank enclosure for hydraulic fluid return lines P,T,A,B

L

194

These letters indicate the pressure (P), tank (T), and the working ports, A and B, of directional control valves. This letter is used to indicate a drain line to tank

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MAINTENANCE: Table 6.1 Sheet 2 of 6 Hydraulic Symbols S XX

This letter plus accompanying numerals is used to identify a particular solenoid.

Y

This letter indicates a proportional flow or throttle valve

K

This letter indicates a pressure relief valve.

X26 or Z36

The letter (X or Z) and accompanying numerals are used to identify a valve and are used to reference that particular valve on the hydraulic parts list.

NG XX

This represents the flow capacity of a particular valve.

P1

The letter that appears on the perimeter of the manifold can be found stamped into the surface of the manifold beside the appropriate piping connection. M3

These symbols, that appear on the perimeter of the manifold indicate locations where pressure gauge readings can be taken. e.g. if the pressure gauge is turned to position 3 (M3) the pressure occurring at M3 (Injection) can be monitored. This symbol represents the heat exchanger with external lines indicating the coolant flow direction. This symbol represents the 40 micron strainer that is immersed in the hydraulic fluid within the tank. If a blockage occurs, the accompanying pressure switch is "tripped" which results in the electric motor being stopped. This symbol represents the hydraulic filler cap and strainer located on the top of the tank. The cap performs three functions: filler, breather and strainer. This symbol represents a filter with electric feedback. This symbol represents the hydraulic fluid level indicator. If the fluid is too low, the accompanying switch is "tripped" which results in the electric motor being stopped.

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MAINTENANCE: Table 6.1 Sheet 3 of 6 Hydraulic Symbols

t

This symbol represents the hydraulic fluid temperature gauge and electrical feedback to the control system. If the temperature exceeds the maximum set limit, the accompanying switch is "tripped" which results in the electric motor being stopped. This symbol represents a one way check valve. This symbol represents a spring loaded one way check valve. This symbol represents a double check valve. Pressure in one line opens the other check valve to allow return flow. This symbol represents a shuttle valve, that allows high pressure flow from only one direction at a time. This symbol represents a return spring. This symbol represents an adjustable return spring. This symbol represents a main drive electric motor. This symbol represents a variable displacement pump (Bosch)

This symbol represents a variable displacement pump (Rexroth)

This symbol represents a fixed displacement pump with one flow direction. This symbol represents an hydraulic motor with one flow direction. This symbol represents an input or output shaft. This symbol represents a shaft coupling.

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MAINTENANCE: Table 6.1 Sheet 4 of 6 Hydraulic Symbols

This symbol represents a fixed orifice, generally used to limit hydraulic pressure shocks or to introduce a time delay in force transmission. The flow rate through the orifice is unaffected by viscosity. This symbol represents a metered orifice that can self compensate to maintain a particular flow rate. This symbol represents a fixed orifice, generally used to limit hydraulic pressure shocks or to introduce a time delay in force transmission. However the flow rate through the orifice is affected by viscosity. This symbol represents a d.c. solenoid that is used to switch directional control valve positions. a

b

This symbol represents a three position directional control valve that can be switched into either position by a d.c. solenoid. This symbol represents a directional control valve. The filled triangles indicate a main spool that is piloted by a smaller hydraulic valve.

Z

Y

F B

B A

F B

F B A

F B

B A F B

This symbol represents a cartridge valve with three areas upon which pressure acts. The bottom area A = 100% the side area B = 160% and the top area F = 160% This symbol is a variation of the symbol above and represents a cartridge valve with three areas upon which pressure acts. Area A is small compared to F, but as above A + B = F

B A

B

This symbol represents a cartridge valve cover plate with two plugged pilot lines, Z and Y.

B

This symbol represents a cartridge valve as above but the black triangle represents precision control notches that allow for soft opening and closing. This symbol is a variation of the symbol above and represents a cartridge valve as above but the black area represents precision control notches that allow for soft opening and closing. This symbol represents a cartridge valve with a 1:1 area ratio, area A = area F. The valve is usually employed in pressure relief circuits.

A

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MAINTENANCE: Table 6.1 Sheet 5 of 6 Hydraulic Symbols F B

This symbol is a variation of the preceding symbol and represents a cartridge valve with a 1:1 area ratio, area A = area F. The valve is usually employed in pressure relief circuits.

B A F

B

This symbol represents a cartridge valve with a 1:1 area ratio, but with an orifice through the middle allowing pressure equalization on areas A and F.

B

A F B

This symbol represents a cartridge valve used to control pressure as the fluid is flowing through it. This is a normally open valve.

B A

F B

This symbol represents a cartridge valve used to control pressure as the fluid is flowing through it. This is a normally closed valve.

B A

This symbol represents an adjustable relief valve, directly operated, normally closed. This symbol represents an adjustable pressure reducing valve, normally open. This symbol represents a proportional pressure control valve, a K valve This symbol represents a proportional flow control valve, a Y valve.

198

A

B

P

T

This symbol represents a three way Moog valve. The main spool is controlled by a servo pilot valve.

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MAINTENANCE: Table 6.1 Sheet 6 of 6 Hydraulic Symbols A

B

P

T

Y4

S1

A

: T

P

PILOT VALVE

X

Y

MAIN VALVE

A A

_

P

B

B

T

X

Y

P

T

This symbol represents a pilot operated proportional directional control valve. The figure shows the main stage valve which is piloted by the Y4 valve. The pilot line to the right side of the main spool runs through the S1 valve which is energized during mold close. The position of the main spool is determined by a position transducer and superimposed upon the pilot valve control circuit. If the solenoid is not energized, the main spool is relieved and shifts to the center position due to the force of the spool centring springs. This symbol represents a double acting cylinder. This symbol represents a double acting cylinder with a single adjustable cushion. This symbol represents a roller and plunger used to mechanically switch a directional control valve. This symbol represents a manual cut off valve, often used in accumulator circuits. If the notch in the center of the handle is in line with the line of flow then the valve is open. If the notch is across the line of flow the valve is closed. This symbol represents a gas charged accumulator.

This symbol represents a stroke limiter for a cartridge valve. These are generally employed with accumulators.

This symbol represents an hydraulic pressure transducer. This symbol represents a non return check valve with adjustable throttle control.

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MAINTENANCE: 4.

HYDRAULIC OIL.

WARNING! ENGEL ADVISES THE USE OF NEW, CLEAN OIL, TO ISO CODE 16/13, IN THEIR INJECTION MOLDING MACHINES. THIS LEVEL OF CLEANLINESS OR BETTER MUST BE MAINTAINED THROUGHOUT THE LIFE OF THE MACHINE. REFER TO ISO 4406 - HYDRAULIC FLUID POWER - FLUIDS - METHOD FOR CODING LEVEL OF CONTAMINATION BY SOLID PARTICLES. USE MINERAL BASED HYDRAULIC OIL WITH A VISCOSITY CLASS OF ISO VG 46 (AT 40 OC) THE USE OF RECYCLED OIL TO OPERATE AN ENGEL INJECTION MOLDING MACHINE WILL VOID THE WARRANTY OF THAT MACHINE. CONTACT ENGEL CONCERNING POSSIBLE WARRANTY ISSUES IF ZINC FREE (ASHLESS) HYDRAULIC OIL IS USED IN THE INJECTION MOLDING MACHINE OR FOR RECOMMENDATIONS OR ADVICE ON HYDRAULIC OIL CHOICE Filling.

If necessary, fill oil tank with appropriate brand name oil before pump start-up, see Table 6.2 (minimum startup temperature of the oil is 15 oC or 59 oF)

NOTE! OIL MUST BE FILTERED BEFORE BEING PUMPED INTO THE OIL TANK. Changing.

Hydraulic oil must be changed after approximately 5000 - 6000 working hours or after testing of an oil sample has indicated contamination and or breakdown of the oil. To change the oil follow these steps: 1. Draw the oil out through the filling pipe with a suction pump and drain off the remaining oil through the drain plug. 2. Remove the cleaning cover from the side the oil tank. 3. Clean the walls and bottom of the oil tank with a cleansing agent in order to remove any residues. 4. Install the drain plug and fit the cleaning cover. 5. Ensure the inset filter screen is installed. 6. Fill with appropriate brand name oil through the filling pipe, to the upper third of the oil level sight glass. 7. Replace filler/breather cap. 8. Do not start the pump for approximately 1/2 hour to allow for settling and degassing.

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MAINTENANCE: 4.1

HYDRAULIC FLUIDS

WARNING! ENGEL ADVISES THE USE OF NEW, CLEAN OIL, TO ISO CODE 16/13, IN THEIR INJECTION MOLDING MACHINES. THIS LEVEL OF CLEANLINESS OR BETTER MUST BE MAINTAINED THROUGHOUT THE LIFE OF THE MACHINE. REFER TO ISO 4406 - HYDRAULIC FLUID POWER - FLUIDS - METHOD FOR CODING LEVEL OF CONTAMINATION BY SOLID PARTICLES. USE MINERAL BASED HYDRAULIC OIL WITH A VISCOSITY CLASS OF ISO VG 46 (AT 40 OC) RECOMMENDED IN THE TABLE BELOW. THE USE OF RECYCLED OIL TO OPERATE AN ENGEL INJECTION MOLDING MACHINE WILL VOID THE WARRANTY OF THAT MACHINE. CONTACT ENGEL CONCERNING POSSIBLE WARRANTY ISSUES IF ZINC FREE (ASHLESS) HYDRAULIC OIL IS USED IN THE INJECTION MOLDING MACHINE OR FOR RECOMMENDATIONS OR ADVICE ON HYDRAULIC OIL CHOICE.

The hydraulic fluid in an Engel injection molding machine serves the following purposes: 1. Power transmission 2. Lubrication 3. Sealing 4. Cooling 5. Cleaning Power transmission

-

Pressurized hydraulic fluid converts hydraulic energy to mechanical energy. For example, to extend and retract cylinders or to rotate a hydraulic motor.

Lubrication

-

The inherent lubricating qualities of hydraulic fluid helps to minimize component wear and tear.

Sealing

-

The hydraulic fluid moistens the various gaskets and pressure seals ensuring leakage will be kept to a minimum.

Cooling

-

The hydraulic fluid absorbs heat from the various machine components and transfers that heat to the oil reservoir where it radiates from the reservoir into the atmosphere.

Clean

-

Normal machine wear introduces minute metal particles into the system. The hydraulic fluid transports these particles to the filtering system of the machine where the particles are separated from the fluid before re-circulation through the system.

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MAINTENANCE: Table 6.2

HYDRAULIC OIL and LUBRICANT COMPARISON

WARNING! ENGEL ADVISES THE USE OF NEW, CLEAN OIL, TO ISO CODE 16/13, IN THEIR INJECTION MOLDING MACHINES. THIS LEVEL OF CLEANLINESS OR BETTER MUST BE MAINTAINED THROUGHOUT THE LIFE OF THE MACHINE. REFER TO ISO 4406 - HYDRAULIC FLUID POWER - FLUIDS - METHOD FOR CODING LEVEL OF CONTAMINATION BY SOLID PARTICLES. USE MINERAL BASED HYDRAULIC OIL WITH A VISCOSITY CLASS OF ISO VG 46 (AT 40 OC) RECOMMENDED IN THE TABLE BELOW. CONTACT ENGEL CONCERNING POSSIBLE WARRANTY ISSUES IF ZINC FREE (ASHLESS) HYDRAULIC OIL IS USED IN THE INJECTION MOLDING MACHINE OR FOR RECOMMENDATIONS OR ADVICE ON HYDRAULIC OIL CHOICE. THE USE OF RECYCLED OIL TO OPERATE AN ENGEL INJECTION MOLDING MACHINE WILL VOID THE WARRANTY OF THAT MACHINE.

Manufacturer

Hydraulic Oil

Ashland Valvoline BP Oil Corp.

AW20

Castrol *!* Chevron

Tribol 943AW Hydraulic oil ISO AW 46

Citgo Petroleum Co. Exxon Esso Fiske Bros. E.F. Houghton A. Margolis & Sons Mobil Shell Sunoco Texaco

Turbinol HL-46

Gear Oil (older m/c only)

Central Lubrication (Oil)

Epcomp.100 Waylube W-30 X 18MD S1000 Energol GR-XP-C220

Way oil Vistac 68

Citgo A/W 46

EP Gear Compound EP 220 Tegra Synthetic 220 EP Compound 220

Nuto H 46 Nuto H 46

Spartan Ep220 (3) Penoled EP 3

Febis K68 (53)

Lubriplate HO-46 APG 90 Hydro-Drive HP-200 MP Gear Oil 90 T.I.P. 100-20 7 M.P.E.P. Gear Lube SAE 90 DTE 25 Lubrite HD 90 Mobile Gear 630 Tellus T 46 Omala 220 Sunvis 832 WR Rando HD46 (B) HD 46

Tower Oil & Techn. Co.

Grease Lubrication (lithium base)

Energrease LS EP2 Dura-Lith EP 2 Ultiplex EP #2

Sliderite 68

Beacon EP2 Nebula EP2

Lubriplate *3V Way Lubricant 297 M.P. 307 Vactra 2 Vacuoline 1409 Tonna V 68 (33) Lubeway 1754 Sunway 1180 Waylube 68

Universal Gear Lube HD 90 Meropa 220 (3) #95 Way & Gear Lube, #47 Way Lube Expr.Gear Lube HG 90

Mobillux EP2 Alvania EP Sunaplex 992 EP GR Multifak EP 2

*!* = Only use with BOSCH RKP Pumps

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MAINTENANCE: VISCOSITY EQUIVALENTS

Grade System

Kinematic Viscosities cSt 40 oC

cSt 100 oC

800 40

ISO

Saybolt Viscosities

SAE SAE SUS SUS AGMA Engine oil Gear OIl 210 oF 100 oF

680

4000

8

200

600

3000

500 30 400 350 300 250

20

460

7

320

6

220

5

140

90 16

150 100 80

50 40

4

100

3

68

2

46

30

80W 20

90

1000

70

500

60

400

55

300 250

50

75W

32

45 150

5

22 15

1

2000 1800 1500 1250

200 6

20

85W

8 7

125

80

40

30

10 9

60

150

2500

100

50

200

150

10W

4

40

15

5W

100 90 70

10

10

55

Viscosities can be related horizontally only, e.g. the following oils have similar viscosities: ISO 460, AGMA 7 and SAE Gear Oil 140. The viscosity / temperature relationships are based on 95 VI oils and are usable only for mono grade engine oils, gear oils and other 95 VI oils.

NOTE! CRANKCASE OIL AND GEAR OILS ARE BASED ON 100O C VISCOSITY. THE "W" GRADES ARE CLASSIFIED ON LOW TEMPERATURE PROPERTIES. ISO OILS AND AGMA GRADES ARE BASED ON 40 OC VISCOSITY.

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MAINTENANCE: 4.2

HYDRAULIC FLUID VISCOSITY

Fluid viscosity is generally regarded as the most important selection factor to be considered when choosing a hydraulic fluid for industrial purposes. Viscosity is the term that refers to a fluid's internal resistance to flow (i.e. thickness). If the fluid selected does not have the correct viscosity, it will not perform satisfactorily in the machine. Viscosity is affected by heat and pressure, high pressures will increase viscosity because the fluid molecules will be "packed closer together" and are more difficult to move. An increase in heat will cause the molecules to move away from each other make the fluid easier to move which will lead to a lower viscosity. Conversely cold fluid is sluggish to move because the molecules are closely packed together. For example; Using a lower viscosity grade than recommended leads to: • excessive leakage • increased wear • loss of pressure • erratic hydraulic operation • lower overall efficiency Using a higher viscosity grade than recommended leads to: • increased pressure drop • higher fluid temperatures • sluggish operation • higher power consumption Engel recommends that viscosity grade 46 (VG 46) be used in all injection molding machines for peak performance. Any deviation from this viscosity grade recommendation could lead to the above mentioned problems. Preheating Program

Engel machines are equipped with programs and procedures to bring the temperature of the hydraulic fluid up to normal operating temperatures. Preheating may be necessary if a machine has been idle for a period of time. As discussed earlier the viscosity of the oil will change, in response to a change in temperature. If a machine is set-up to operate with oil at a particular viscosity to achieve specific flow and pressure characteristics and the viscosity of the oil is higher because the oil is cold, flow and pressure characteristics will not be right. The machine will not perform as expected.

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MAINTENANCE: In order to preheat the oil to the "set value" operating temperature, oil is directed through a valve (Z3 on 100 Ton and smaller machines and Z36 on 125 Ton and larger machines) under system pressure back to the tank. The minimum temperature must be reached before the machine can be switched to automatic cycle. The specific directional control valve that controls this function is S10. If the machine has two pumps S9 directional control valve controls a second preheating valve (Z37) in the same way that S10 controls Z36. Concept of Power

Power is defined as the rate of doing work. The most common method of measuring power is to use the term horsepower. Specifically, horsepower is the amount of weight that a horse can lift a distance of one foot in a time of one second. Mechanical:

Power

=

1 Horsepower

Force x Distance ----------------------Time

=

550 lbs. x 1 Foot -----------------------1 Second

Electrical Power

=

1 Horsepower

Voltage x Current Flow =

745.7 Watts

Hydraulic Power

=

1 Horsepower

Pressure x Volumetric Flow

=

1714 PSI x 1 GPM -------------------------1714

Heat in Hydraulics Hydraulic systems develop heat in normal operation in the following ways: • through pipes and fittings • through flow controls • over relief valves • internal leakage of pumps and motors

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MAINTENANCE: All of these show a drop in pressure as the hydraulic fluid flows past these points. Since horsepower is represented by the equation of pressure multiplied by flow, it is obvious that horsepower is being lost at the above mentioned points, since they do no useful work. The wasted horsepower shows up as heat in hydraulic systems, the higher the pressure drop, the higher the horsepower loss. If the flow rate in gallons per minute (GPM) and the pressure drop in pounds per square inch (PSI) are known, then the heat generated by the system and therefore the horsepower lost, can be calculated as follows:

(1)

(2)

(3)

BTU ----HR

=

1.5 x GPM x PSI

1 Horsepower

BTU/HR ---------2545

=

=

2545 BTU ------------HR

Horsepower lost/HR

Consider the following example:

a.) 20 GPM pump flow b.) 3000 PSI max pressure. c.) 1500 PSI load induced pressure

3000 PSI

20 GPM

1500 PSI LOAD INDUCED PRESSURE

A6410117

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MAINTENANCE: The horsepower required to operate at full speed and full load will be:

HP

20GPM x 1500 PSI ------------------------1714 x .85 (eff.)

=

=

20.6 HP

In this case, the total flow is required for full speed but maximum pressure is not required to overcome the load. Therefore, the relief valve will stay closed and little heat will be generated. Assume now that 50% speed is required and 50% of the previous load is being lifted. The heat generated would be: BTU -----HR

=

1.5 x 10 x 3000

=

45000

BTU ------HR

This represents only the heat generated from the 10 GPM through the relief valve at 3000 PSI. Heat is also generated due to the pressure drop across the flow control valve.

750 psi LOAD INDUCED PRESSURE

3000 psi RELIEF VALVE SETTING

BTU ----HR

=

1.5 x 10 x 2250

=

33750

BTU -----HR

In total, 33750 plus 45000 BTU / HR will equal 78750 BTU / HR generated. If this is converted into HP, we will have: 78750 BTU --------------2545 HR

=

31 HP

To run the load up at 50% speed and 50% of full load condition, the loss will be the equivalent of 31 HP in heat per hour.

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MAINTENANCE: Lowering the load under the same speed and load conditions will waste the total 41 HP input since the potential energy in the load does the work of lowering the load. Therefore, the BTU's generated by lowering the load will equal: BTU ----HR

=

1.5 x 20 x 3000

=

90000

BTU --HR

generated to raise load

=

78750

BTU --HR

generated to lower load

=

90000

BTU ---HR

Consider the following:

Raising and lowering the load for one hour, will generate: Raise 78750 BTU x 0.5 HR = 39375 Lower 90000 BTU x 0.5 HR = 45000 39375 plus 45000 = 84375 BTU / HR 84375 BTU / HR will be generated just raising and lowering the load. This is enough energy to heat an average three bedroom home to 70o F on a zero degree day.

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MAINTENANCE: 4.3

FILTRATION

The majority of hydraulic problems can be related to dirt or contamination within the hydraulic components. The extremely close tolerances to which most hydraulic components are manufactured make the hydraulic system intolerant to even small amounts of contamination. Sources of contamination include: 1. Inherited contamination 2. System generated contamination 3. Externally introduced contamination Inherited Contamination

A barrel of new oil from the refinery is usually quite "dirty" by hydraulic cleanliness standards and cannot be considered as satisfactorily clean. Also, when new machines are assembled there are relatively large amounts of dirt within the system. The new machines are thoroughly flushed out before delivery to the customer. Oil added to the machine, after delivery must be properly filtered. System Generated Contamination

During normal machine operation, friction in pumps, valves, cylinders and motors causes wear of the sliding surfaces. The effect is to generate microscopic particles throughout the system which have an abrasive effect on the system as a whole . This, in turn, produces more particles and increased wear in a snowballing effect until the contamination and resulting wear reaches a critical level. Externally Introduced Contamination

Generally, the industrial environments that Engel machines operate in, are not the cleanest. During normal operation, the level in the reservoir is constantly changing. For example, when a cylinder extends, the oil level drops and the reservoir inhales air contaminated with dust and water vapor. These contaminants mix with the oil and then enter the system. Engel systems are equipped with a number of devices to remove contamination from the hydraulic fluid. 1. Strainers 2. Filters 3. Magnets 4. Tank Baffles

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MAINTENANCE: Strainer

Engel uses a 40 micron suction filter located between the reservoir and the pump inlet. The suction filter is immersed horizontally within the tank, at this location there is very little pressure differential or fluid velocity across the filtering element. This arrangement increases the filter's efficiency since the low fluid velocity will not disturb the particles already collected, and the low pressure differential will not encourage any of the collected particles to be forced through the filter. This strainer should be cleaned one month after initial start-up and semi-annually thereafter. Filters

Engel employs a pressure filter downstream from the pump. This is a 10 micron pressure filter which provides maximum protection for the machine components directly downstream from the filter outlet. It is designed to handle maximum system pressure with a high degree of filtration and relatively long service life. Machines equipped with a Moog servo-valve will have an additional filter fitted to the injection manifold. This is designed to provide the extra filtration normally required for servo-valves. Magnets

Located within the casing of the suction filter is a permanent magnet which is designed to collect any minute particles of steel within the fluid. These steel particles occur due to the friction involved during the normal operation of the machines (i.e. pump friction, valve friction, etc.) Tank Baffles

Engel machine reservoirs are designed to allow time for heat radiation (i.e. cooling) and to allow time for contaminants within the hydraulic fluid to settle to the bottom of the tank and out of the mainstream of fluid flow. For example, water cannot be removed from the system by filtration, but it will settle out. This is achieved by strategically placing baffles in the tank to slow the flow of oil from the return side of the tank to the suction side. There is an inspection cover located on the side of every Engel machine to allow for the periodic cleaning of the inside of the reservoir.

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MAINTENANCE: 4.3.1

HIGH AND MEDIUM-PRESSURE FILTER

High or medium pressure filters are routinely installed directly after the pump outlet. Machines which are equipped with a Moog Valve will also have a high or medium pressure filter installed in the valve pilot line.

ELECTRICAL INDICATOR

POP UP INDICATOR BYPASS SENSOR

FILTER ELEMENT

BYPASS VALVE

FILTER BOWL

Figure 6.6 High or Medium Pressure Filter.

There are two types of alarm indications for these type of pressure filters: Mechanical type alarm. The mechanical type alarm which has an indicator which pops up when the filter is dirty. Cold starts may cause the contamination indicator to pop up, but once the machine is up to normal running temperature and the pop up indicator will not stay down when pressed the filter should be changed. This type of filter alarm should be visually checked every day.

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MAINTENANCE: Electrical type alarm. The electrical type of alarm indicator will cause the machine to stop if the alarm is tripped. Cold starts may cause the contamination indicator to pop up and a warning signal sent to the controller, but once the machine is up to normal running temperature and the pop up indicator will not stay down when pressed and/or the warning signal continues, the filter should be changed. The controller is always "looking" for a 24 volt signal to indicate that the filter is OK. If the signal is not present, the controller assumes that the filter is dirty, stops the machine, and indicates the problem on the error page.

NOTE! Maintain an adequate supply of spare elements; disposable elements cannot be cleaned. Filter Element Replacement. 1. Shut system down and ensure filter pressure is zero 2. Unscrew filter bowl - counterclockwise 3. Clean filter bowl with suitable cleaning solvent. 4. Remove the filter element from the filterhead, a side to side movement may be necessary to free the element. 5. Check all "O" rings, "back up rings and seals for damage, replace if necessary. 6. Ensure that the part number on the new element corresponds with the part number on the filter nameplate. 7. Open one end of the plastic bag and push the element over the receiving piece in the filter head. 8. Remove the plastic bag completely. 9. Screw the filter bowl over the element until it comes to a full stop and then back off the bowl 1/8 to 1/2 turn.

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MAINTENANCE: 4.3.2

HYDRAULIC SUCTION FILTER

The suction filter prevents dirt particles from the oil tank from entering the pump and consequently the entire hydraulic system. Metal particles are collected on a magnetic bar inside the filter. If the filter should become totally clogged, a vacuum switch signals the problem to the control unit. The result is an immediate shutdown of the pump motor and the heat zones are switched to standby temperature settings. Before a restart can be attempted the suction filter must be dismantled and cleaned.

2

1

3

5

6

10

11

7

8

9

4 Figure 6.7 Suction Filter

Spare parts list : Part 1 Valve actuator Part 2 Seal Part 3 Filter cover with screen seat Part 4 Cap screws Part 5 "O" ring Part 6 Nut Part 7 Valve disk Part 8 Valve spring Part 9 Valve box Part 10 Screen insert Part 11 Magnetic bar

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MAINTENANCE: Screen cleaning instructions

To remove the screen insert: • Place a suitable container under the drip tray drain plug and remove the drain plug. • Screw the valve actuator out fully, to close the valve. • Remove cap screws from the end cover. • Remove the end cover, screen and magnetic bar as one. • Lightly tap the screen to release it from the taper in the end cover. • Clean the screen with a suitable cleansing agent ( benzene, benzole etc. ). • Strip off stubborn dirt particles with the end of a soft pencil. • Clean the magnetic bar. • Fit the screen into the taper of the end cover. • Ensure that the valve actuator is fully screwed out before fitting the end cover / filter assembly into the valve box. • Ensure that the "O" ring is properly seated, and hold the end cover assembly / filter to the valve box. • Fit the cap screws, and tighten them evenly in rotation around the end cover. • Screw the valve actuator in fully to allow oil flow. The suction filter shown in figure 6.8 is often used on smaller machines.

FILTER ELEMENT OIL IN

OIL OUT COVER

VALVE

OIL IN

A6311512

Figure 6.8. Suction Filter

To remove and clean this style of filter: 1. Place a suitable container under the drip tray drain plug and remove the drain plug. 2. Unscrew filter cover and withdraw filter element. The valve will close during the unscrewing to prevent the discharge of oil from the tank. 3. Clean filter element by immersing in a suitable cleaning solvent and moving the element around to dissolve and dislodge the dirt deposits. 4. Check seals and reinstall.

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MAINTENANCE: BY-PASS FILTERS

Filtroil - By-pass filtration unit. Full time by-pass filtration is an effective way of improving the overall filtration system and also the quality of the hydraulic oil used. Full flow filters are limited in their ability to remove and hold small particles and maintain proper circulation pressure. The Filtroil by-pass system allows a consistent low pressure oil flow rate from a high pressure line of the hydraulic system (between 100 and 3000 psi), into a filter housing and through a cellulose filter element. The by-pass system filters approximately 10 to 20% of the oil per hour, over the course of a few weeks the system oil will be upgraded and maintained at approximately 2 to 5 grades cleaner than new oil. Many hydraulic and machine problems can be traced back to contaminated oil. Construction and principle of operation. The Filtroil system consists of : 1. Filter canister. 2. Filter lid. 3. Tee bar / oil feed. 4. Pressure gauge. 5. Pressure compensated flow control valve. 6. Shut Off valve. 7. Test / Drain valve. The filter element is effectively sealed inside the canister of the unit (See figure 6.9), the bottom of the element is seated on two ridges , one inner and one outer, the lid is tightened down onto the element to prevent oil from flowing down the sides of the element.. The element has a polypropylene compression skirt around the bottom to ensure that no oil escapes to tank before it is forced through the filter element. The unit is designed to take hydraulic oil at between 100 to 3000 psi, through a flow control valve, which is acting as a pressure reducing valve. The oil is then feed up through the middle of the tee bar to the top of the cellulose filter, where under pressure the oil is forced through the filter to the bottom of the unit which is at atmospheric pressure, and the oil flows to tank.

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MAINTENANCE: The nature of the filter element, which is constructed as a roll of many layers of lightweight cellulose fibre, when compressed by the oil pressure is that the layers become progressively compacted, as the bottom of the filter is neared. This has the effect of filtering progressively smaller particles as the oil is forced to the bottom of the unit. Cellulose fibre also has the ability to absorb moisture and the element can hold approximately half a pint of water, but on the downside the water degrades the elements filtering ability, the water tends to hold the layers apart which prevents the element from successfully trapping the smaller particles. The element will trap suspended particles as small as 0.1 micron, but will not affect any oil additives because the additives are in solution and are effectively part of the hydraulic oil. TEE BAR / OIL FEED

"U" RING GASKET

LID

OIL WAY TO TOP OF ELEMENT

FILTER ELEMENT

FILTER SEATING RIDGE

CANISTER

MESH

OIL RETURN TO TANK PRESSURE GAUGE TEST/DRAIN VALVE

Figure 6.9 Filtroil By-pass Filter System

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MAINTENANCE: Periodic Maintenance.

To ensure that Filtroil by-pass system is working at maximum efficiency, carry out the following regular checks: Daily.

Check pressure gauge reading

Less than 75 psi = OK More than 75 psi = clogged filter needs changing.

3 Monthly.

Check gasket set

Replace if defective.

Change filter element

Refer to element change section in this chapter.

Check pressure gauge function.

Cycle Shut Off valve and observe rise and fall of gauge.

Oil sample analysis

Take sample for analysis using Test / Drain valve.

Check flow rate through Flow Control Valve to Filtroil unit.

Note time required to fill container of known size, check result against specifications for unit (Range 0.3 to 1.5 gallons per minute).

6 Monthly.

Insert flow meter in oil line to filter unit, check as before. Flow rate through Control Valve

Model

BU-50

BU-100

BU-200

BU-400

0.3GPM

0.5GPM

0.75GPM

1.5GPM

Filtroil Filter Element Change.

To change the element proceed as follows: 1.

Turn off the Shut Off Valve, ensure pressure gauge reads zero.

2.

Slowly unfasten and remove Tee- Bolt, to allow any oil left inside the housing to escape to tank.

3.

Place container under Test/Drain valve and open to fully drain the canister.

4.

Remove the lid and "U" ring gasket.

5.

Using hooks on filter, slowly remove filter. Slight side to side motion may be required if any resistance is felt.

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MAINTENANCE: 6.

Fit new filter element, push down lightly on the filter to ensure a good seal.

NOTE! A. B.

PLASTIC SKIRT AT BOTTOM OF FILTER ELEMENT MUST BE IN PLACE. NEVER POUR OIL ON TOP OF NEW ELEMENT.

7.

Fit the "U" ring gasket on the top lip of the canister.

8.

Fit lid and Tee- Bar, carefully hand tighten the Tee-bar ensuring that the lid does not turn too.

9.

Return Test/Drain valve to Off position.

10. Slowly turn the Shut-off Valve to the on position. 11. Check connections for leaks. 12. Ensure that the pressure gauge rises to between 20 and 40 psi as the Filtroil system matches the machine system. 13. Fill out element change sticker with the correct date and stick to Filtroil canister. 14. Allow 24 hours for the old filter to drain into a suitable container, then dispose of the filter in the approved manner.

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MAINTENANCE: By-Pass Filter System Trouble Shooting.

Symptom

Cause

Solutions

Gauge always reads too high

Element saturated with contaminants

Change element

Gauge reads incorrectly

Check function of gauge

Flow control valve installed backwards

Install flow control valve correctly

Hole in bottom of Tee Bar clogged

Remove Tee Bar and clean out hole

Oil poured on top of element at time of change.

Replace element.

Element installed incorrectly

Check installation of element.

Restriction in outlet side of unit.

Check outlet at bottom of canister and outlet hose for restriction.

Improper sampling.

Review sampling methods, use sampling valve on unit.

Make up oil added without prefiltering.

Always filter new oil.

Contaminants introduced during repairs.

Do not sample oil after repairs.

Shut off valve not fully open.

Open shut off valve fully

Plastic skirt missing from bottom of element.

Replace element.

Incorrect tap-in port chosen on hydraulic system (pressure may be dropping to less than 100 psi).

Unit requires hydraulic pressure of between 100 and 3000 psi, reinstall shut off valve.

Flow control valve is clogged.

Remove valve clean and check flow rate, replace if not to specifications. See page 6-11 for flow rate.

Oil analysis shows unchanged or worsening ISO code.

Gauge reads too low or needle never rises over time.

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MAINTENANCE: Oil Sampling.

Regular oil sampling is recommended to monitor the state of the hydraulic oil in the machine, records kept over the course of a few months will indicate any deterioration in the machine or in oil quality. Laboratory testing of oil samples will provide the following information: Particle count

- The number of actual particles, listed by size, in one millilitre of oil.

Viscosity classification

- This number is a leading indicator of hydraulic fluid condition, and should be compared with the original specification.

TAN (Total Acid Number) - The measurement of the amount of oxidation that hasoccurred in the oil. ISO Code

- The two part number indicates the cleanliness of the hydraulic fluid, the first number is the total number of particles greater than 5 microns and the second number indicates the total number of particles greater than 15 microns in a one millilitre sample. The greater the ISO number the greater the potential for wear.

Water Content

- The amount of water in a one millilitre sample as a percentage.

Spectroscopic Analysis

- This lists the wear metals and additives in the oil sample and are specified in parts per million, this information is useful in tracking build up of certain metals in the fluid which may indicate excessive wear in a particular part of the machine.

Careful attention should be paid to the oil analysis charts of each machine and any signification rise in metals present in the oil sample noted. A prediction can be made, based on the oil analysis information, of an imminent failure of that machine and preventive action could be taken to prevent any other damage to the machine. Other information contained in the oil analysis chart can indicate when an hydraulic fluid is coming to the end of it's useful life and requires changing.

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MAINTENANCE: 5

HYDRAULIC MOTORS

ENGEL injection molding machines use hydraulic motors to convert hydraulic energy into rotary mechanical energy in order to turn the plasticizing screw. The tooth ring motor below shows a gearwheel set with a fixed gear rim and an inner gear wheel.

A

B GEAR RIM

1 7

C INNER GEAR

GEARWHEEL SET 2

2

3

6 4

5 15

O

6 CARDEN SHAFT

OUTPUT SHAFT

In response to a pressurized flow of oil, the inner gear would be forced away from a tooth slot and would rotate about its axis towards the following tooth slots. As the inner gear rotates towards the following tooth slot, this area would be connected to tank to allow the fluid contained in this area to escape. The pressurization and connections to tank are accomplished through a spool valve built into the output shaft. The rotation of the inner gear is transmitted to the output shaft via a "Carden shaft" which is connects the inner gear and output shaft but is free to float and follows the orbit of the inner gear. In the figure above, assume that the inner gear wheel is turning counter-clockwise, .the relative positions of the inner gear are shown as the gear rotates around the inside of the gearwheel set "A"

shows the gear wheel in a position just before the bottom tooth engages tooth slot 4.

"B"

shows the gear wheel in a position just before the extreme left tooth engages tooth slot 6.

"C"

shows the gear wheel in a position just before the upper right tooth engages tooth slot 2.

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MAINTENANCE: The motors used on Engel machines, have rollers on the gearwheel rim, permitting higher operating pressures and providing a longer operating life. Instead of a spool valve providing the pressure and tank connections, this motor type has a separate disc type distributor valve that performs the pressurization and tank venting functions. When changing a leaky retaining ring on the Danfloss OMR motors, care should be taken not to disconnect the output shaft from the carden shaft . If the shafts do become disconnected they must be oriented as shown in figure 6.4A, or the motor will not function correctly. To achieve correct orientation, the keyway in the output shaft must be set at 15o from an imaginary line drawn down through the center of the inner gear. Danfoss Motor (30 - 300 Ton)

Engel machines of 30 to 300 Tons are usually equipped with the Danfoss Screw Drive Motor. (types OMA, OMR, OMV)

DANFOSS SCREW DRIVE MOTOR

Figure 6.11 Rotary Piston Motor (Sauer)

Previously Engel machines of 400 Tons and up have used the Sauer rotary piston screw drive motor (optionally on the 300 Ton).

ROTARY PISTON SCREW DRIVE MOTOR Figure 6.12

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MAINTENANCE: Description of Operation

Shaft rotation is accomplished; high pressure fluid flows through axial ports in the shaft. The eccentric on the crankshaft has two opposing flats and ports the fluid to the pentagon, then through the hollow piston and into the cylinder chamber. The result is that the high pressure fluid produces a force on the lever arm of the eccentric and turns the shaft. Force is not transmitted by the piston, but by the hydraulic pressure acting directly on the eccentric. The piston provides a sleeve for sealing the cylinder chamber. The pentagon does not rotate, however, it does move in an eccentric pattern as high pressure shifts from one cylinder to another.

1

2

4

3

Figure 6.13. Rotary Piston Pump.

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MAINTENANCE: 5.1

HYDRAULIC PUMPS.

All Engel machines (30-450 Ton) use variable displacement pumps and some Engel machines (300-450 Ton) use a combination of both variable displacement and fixed displacement pumps. The larger Engel machines (550 -3500 Tons) employ a configuration of fixed displacement pumps employing a load sensing pressure relief system. The flow of variable displacement pumps can be adjusted to accommodate for varying system requirements. The flow of fixed displacement pumps cannot be varied, unless the input speed of the electric motor is varied. All the electric motors used run at a constant 1800 RPM, so the output of the fixed displacement pump will be constant as well. 5.1.1

VARIABLE DISPLACEMENT PUMPS

To save energy, all Engel machines use a variable displacement pump equipped with a load sensing control. The load sensing control virtually eliminates heat related problems in the hydraulic system. Machines 150 Ton and up, use radial piston pumps and smaller machines use in-line axial piston pumps. Radial Piston Pump.

The radial piston pump is an internal admission, pilot valve controlled reciprocating pump with pistons arranged radially in a star-shaped cylinder block which abuts an eccentric stroke ring through hydrostatically balanced slipper pads. The output delivery of the pump can be varied or reversed by altering the eccentricity of the stroke ring with the control pistons.

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MAINTENANCE: Mode of operation

The drive torque is transferred from the pump shaft to the star-shaped cylinder block free from any transverse forces via a cross-disc coupling. The cylinder block is supported on the control journal which rotates on the pump shaft. The radial pistons in the cylinder block is supported in the stroke ring with hydrostatically balanced slipper pads. Piston and slipper pad are joined by a ball and socket joint which is held in place by a lock ring. The slipper pads are guided in the stroke ring by two overlapping rings and, when running, are forced against the stroke ring by centrifugal force and oil pressure. As the cylinder block rotates, the pistons perform a reciprocating motion due to the eccentric position of the stroke ring, the piston stroke being twice the eccentricity. The eccentric position of the stroke ring can be altered by means of two diametrically opposite control pistons in the pump body. The oil flow to and from the pump passes through ducts in the body and control journal. The flow is controlled by the suction and delivery ports in the control journal. The pressure forces generated inside the pump are absorbed by surfaces which are almost fully hydrostatically balanced. The rolling bearing supporting the drive shaft is subjected to external forces only.

Figure 6.15. Radial Piston Pump - Stroke Control. Hydraulic stroke-ring adjustment

The hydraulic control pistons 1 and 2 are used to vary the eccentricity of the stroke ring. The effective areas of the two pistons differ by a ratio of 2:1. The pistons are arranged vertically to the direction of delivery flow. The smaller piston (2) is constantly subjected to high pressure and presses the stroke ring against the larger control piston(1). Depending upon the operating state, the larger control piston is either blocked by the control valve or is subjected to pressure or is relieved of pressure. As a result, the stroke ring is either held stationary or moves in one or the other direction accordingly. When doing so, it "rolls" on the inside of the housing wall.

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MAINTENANCE: The control pistons are so designed, that under all circumstances they are powerful enough to master the reaction power of the drive unit, the forces of gravity and the frictional forces. On pumps with one direction of flow, the control pressure is taken directly off from the high pressure channel in the control journal. From here, it passes through additional control bores to control piston 2 and to the control valve. The direction of rotation is determined by the position of the control-oil bore on the "shrunk-on" control journal, and cannot be changed. In-line Axial Piston Pump

Figure 6.16. In-line Axial Piston Pump

The in-line variable displacement piston pump develops a flow rate, dependent upon the angle of its controlling swashplate. As the angle of the swashplate increases from vertical, the displacement of the pump increases. Similarly, as the angle decreases the displacement of the pistons decrease towards a position of zero pump output. As the cylinder block rotates, it carries along each of the reciprocating pistons. During half of the revolution, the pistons are being pulled from their bores causing oil to be drawn into the pump. During the other half of the revolution, the pistons are being pushed into the bores causing oil to be forced out of the pump. Load Sensing Controls

Load sensing controls react to the pressure drop across the flow valve and so if the pressure drop can be controlled, then so can the flow rate. The pressure drop, and therefore the flow rate, can be affected by the following variables: 1. If the flow valve inlet is assumed to remain constant and the load pressure at the outlet increases, the pressure drop would decrease. The net effect would be a system slowdown resulting from the increased load.

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MAINTENANCE: 2. 3.

4.

If the flow valve inlet pressure increased while the outlet pressure remained constant, the pressure drop would increase. The net effect would be a system speed-up. By opening and closing the flow control valve the resistance to flow is changed. The lower the resistance, the less pressure drop is needed from the inlet to the outlet for any particular flow rate. The temperature of a fluid affects its viscosity and, therefore, its resistance to flow. Hot oil flows more easily than cold oil through a given restriction.

The load sensing control is based on the idea that if a constant pressure drop is maintained across an orifice, then flow control will be constant as well.

Figure 6.17. Load Sensing Diagram.

In Figure 6.17 a pressure drop of 10 bar is shown across the flow valve (measuring orifice). The lower pressure occurs after the flow valve and the higher pressure occurs from the pump to the flow valve inlet. The higher pressure of the flow valve inlet is also felt on the slide valve working against the spring. The lower pressure of the flow valve outlet is felt in the spring cavity and when this pressure is combined with the psi rating of the spring, the pump is in balance, delivering just enough flow to maintain the 10 bar pressure drop across the flow valve. If the load at the actuator was reduced, an immediately drop in load induced pressure at the flow valve outlet would be evident. Since the pressure drop would increase, the higher pressure of the flow valve inlet side would shift the slide valve to the left causing the larger control piston to be vented to tank. The smaller piston would then be able to shift the pump stroke ring to a position of lower flow capacity until the 10 bar pressure drop was re-gained. If the load induced pressure increased, there would be a decrease in the pressure drop and the system would slow down unless the pump could increase the pressure drop again.

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MAINTENANCE: The increase in load induced pressure would increase the pressure acting on the slide valve forcing it to the right and loading the larger control piston with system pressure. This causes the pump to increase its output flow until the resistance to this flow creates a pressure at the inlet of the flow valve, 10 bar higher than the pressure at the outlet. The pressure pilot valve (see Figure 6.17) limits the maximum feedback pressure to the load sensing control. When the load induced pressure exceeds the pressure pilot valve setting, the valve opens and limits the maximum force available to push the valve to the right. As soon as the pressure at the pump outlet exceeds the limited load induced pressure plus spring force, the slide valve moves to the left causing the pump to go into "deadhead". The pump compensates and supplies only enough fluid to maintain system pressure and replace leakage losses. The calibrated orifice limits the control oil flow when the pilot valve operates. If too much flow potential were allowed in this control line, the pressure override characteristic would adversely affect the proper operation of the pump. Pressure override is the difference between full flow pressure and cracking pressure. On smaller machines, the Rexroth in-line axial piston pumps are used, which are functionally different to the radial piston pumps of Bosch. The load sensing unit, however, works in the same manner for both pumps.

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MAINTENANCE: Balanced Vane Pump

When a fixed displacement pump is required on an Engel machine, a balanced vane pump is often used. Figure 6.18 below shows the major components.

Figure 6.18. Balanced Vane Pump

The balanced vane pump comprises a rotor, an eccentric cam ring, and vanes. The rotor is generally keyed to the drive shaft and is turned by the prime mover. Around the circumference of the rotor are machined slots which hold the vanes in place. Only the drive shaft, rotor and vanes move when the pump is in operation. All other parts remain stationary. When the rotor initially turns, centrifugal force causes the vanes to follow the contours of the outer eccentric cam ring. Therefore, each vane is fully extended and fully collapsed during each revolution. This pump is termed "balanced" because it has two pressure outlets and two suction inlets. As the rotor turns, at the inlet port, a vane starts to extend and collects an increasing volume of oil. The vane continues turning towards a position in the cam ring which, because of its decreasing volume, pressurizes the fluid and forces it out through the outlet port. The same action is occurring at the other side of the pump which has the effect of offsetting any hydraulic forces or loading on the rotor and pump bearing. After the vane starts to "pick up" fluid from the inlet port, the back of the vane is subjected to "system pressure" which forces the vane out against the eccentric cam ring. This prevents the fluid, which will be subjected to the decreasing volume area during pressurization, from escaping the pressure area. At Engel, we use the dual vane design which provides a double seal between the pumping chambers and allows for hydrostatic balancing of the vane which reduces vane tip loading.

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MAINTENANCE: 5.2

CHECK VALVES.

Basic Check Valve.

The check valve comprises a stationary seat, moveable poppet and spring as shown in figure 6.19. The valve is initially closed against flow until the pressure at the inlet, working over the exposed area of the poppet, is sufficient to overcome the spring. Once the poppet is unseated, the fluid flows around and through the poppet to the outlet

CHECK VALVE SYMBOL

BASIC CHECK VALVE (NON RETURN)

POPPET

A6411540

INLET

OUTLET

SPRING

Figure 6.19.

When flow stops, pressure in all parts of a hydraulic circuit equalize. As the pressure equalizes, the hydraulic forces on both sides of the poppet become nearly equal. The valve actually closes when the output pressure plus the spring tension is equal to the input pressure, the output pressure is in fact lower than the input. The function of the check valve is to capture a column of fluid prevent back flow. Check valves are available in various designs, but the guided poppet type is preferred for two reasons: 1. The guided poppet always makes contact with the seat squarely and in the same position. 2. The guided poppet does not chatter at high flow rates, unlike the unguided versions.

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MAINTENANCE: TYPES OF CHECK VALVES

BALL

POPPET

GUIDED

CARTRIDGE

POPPET Figure 6.20 5.2.1

PILOT OPERATED CHECK VALVES.

The pilot operated check valve performs as a simple check valve, in that it allows free flow in one direction and checks the flow in the other. The pilot section allows the check valve to be piloted open at times when reverse flow is required.

PILOT CONTROLLED CHECK VALVE

ACTUATOR

HYDRAULIC SYMBOL

DIRECT CONTROL VALVE

Figure 6.21

As shown in figure 6.21 the pilot piston area is larger than that of the check valve poppet and therefore exerts a greater force which will unseat the check valve and allow reverse flow.

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MAINTENANCE: With the direct control valve in the central position the load is held in a static position because: • The pump flow is divert to tank through the relief valve. • The check valve traps a column of fluid under the actuator piston. • The pressure on the faces of the pilot piston and check valve poppet is vented to tank. With the direct control valve extended to the left the load will be raised because: • The pump flow and pressure is applied to the face of the check valve poppet. • The valve is unseated and allows fluid to flow through to the actuator. • The top side of the actuator and pilot piston are vented to tank. With the direct control valve extended to the right the load will be lowered because: • The pump flow and pressure are diverted to the top of the actuator. • The pump pressure is also applied to the face of the pilot piston. • The check valve is unseated. • The face of the check valve poppet is vented to tank. • The fluid from the bottom of the actuator can flow through the check valve to tank. Applications of pilot operated check valves: 1. Load holding; when the check valve is the only sure way to lock a suspended load, which is affected by gravity, in position. 2. Preventing cylinder chatter; when the load has a tendency to run ahead of the load.

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MAINTENANCE: Sandwich mounted twin pilot operated check valves.

A sandwich mounted twin pilot operated check valve is mounted conveniently between the directional control valve and the sub-plate to provide two way load holding capability.

LOAD SIDE A1

B1

SPRING

TWIN CHECK VALVES

DIRECTIONAL VALVE PILOT PISTON

A

B

POPPET

DIRECTIONAL VALVE SIDE

A6411544

Figure 6.22

With the directional valve in the central position, both sides of the pilot piston and the face area of the check valves are vented to tank. The cylinder is positively locked against motion in either direction as the check valves are closed and have trapped a column of fluid on both sides of the actuator. When the directional valve is shifted to the right the actuator piston extends because: • The pump flow and pressure are diverted to the face of the right-hand check valve poppet. • The right-hand poppet is unseated and the fluid flows to the actuator. • The pressure also shifts the pilot piston to the left. • The left-hand check valve poppet is unseated. • The left-hand section of the actuator is vented to tank. • The left-hand section of the pilot piston is vented to tank. • The fluid from the left-hand side of the actuator flows to tank.

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MAINTENANCE: When the directional valve is shifted to the left, the actuator piston retracts because: • The pump flow and pressure are diverted to the face of the left-hand check valve poppet. • The left-hand poppet is unseated and the fluid flows to the actuator. • The pressure also shifts the pilot piston to the right. • The right-hand check valve poppet is unseated. • The right-hand section of the actuator is vented to tank. • The right-hand section of the pilot piston is vented to tank. • The fluid from the right-hand side flows to tank.

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MAINTENANCE: 5.3

PRESSURE RELIEF VALVES.

The purpose of a relief valve is to limit the maximum pressure within a system to which it is connected. Relief valves are normally placed near to a load, such as a pump, and connected in parallel with the load. The oil has two possible paths to flow in, either into the system or through the valve to tank, depending upon which path has the least resistance. Therefore any problem or blockage ahead in the system restricting flow and thereby pressure can be vented to the main reservoir tank, once the pressure has overcome the setting of the relief valve. The figures below show in simplified form the pressure relief valve in circuit and the symbols found on hydraulic circuit diagrams

G

LOAD

G

RELIEF VALVE

LOAD

RELIEF VALVE

p

p PUMP

PUMP A6411554

TANK

TANK

Figure 6.23

Directly operated pressure relief valves are simple in design and effective in low flow high pressure applications such as thermal expansion relief or where an infrequent safety duty is required. they are also highly effective as pilot relief valves for pilot operated pressure control.

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MAINTENANCE: 5.3.1

PILOT OPERATED PRESSURE RELIEF VALVES.

The pilot operated pressure relief performs the same function as the directly operated valves in that it serves to protect the system components from over pressure, but is capable of relieving more than 75 GPM. The pilot operated pressure relief valve is basically two relief valves in one unit. One section handles high pressure, low flow and the other handles high flow, low pressure. In the figure below of a pilot operated relief valve, the system oil pressure is applied at the bottom of the poppet, but because the top of the poppet has trapped oil working on a slightly larger surface area plus a spring the poppet stays closed. When the system pressure increases passed the setting on the pilot valve, the pilot opens relieving the oil on top of the poppet and allowing the system pressure to open the poppet even further until the pressure decreases and the pilot valve shuts thereby closing the poppet.

VALVE ADJUSTMENT

PILOT RELIEF VALVE

SIMPLE PILOT OPERATED RELIEF MAIN VALVE POPPET

SYSTEM PRESSURE

Figure 6.24.

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MAINTENANCE: 5.3.2

DIRECTLY CONTROLLED PRESSURE REDUCING VALVE

The pressure reducing valve is designed to maintain a secondary circuit at a constant pressure, usually lower than the primary circuit. The pressure is set by an adjusting screw and spring tensioner at the end of the valve. The valve is a normally open device and while the primary pressure is at or below the preset value of the valve, the aperture will remain fully open. Any pressure increase in the secondary circuit is sensed at the valve and when the increase overcomes the opposition of the spring tensioner, the spool is moved up the valve causing the output aperture to be restricted reducing the flow and thereby the pressure. As the pressure is reduced the force acting on the spool is reduced and the hydraulic pressure is balanced against the spring. If the pressure within the secondary circuit drops the aperture will open allowing greater flow and thus increasing the pressure. The reducing valve aperture continually varies in response to pressure changes in the secondary circuit to maintain a constant pressure. If the pressure build up in the secondary circuit increases, even though the reducing valve aperture is completely shut off, the excess fluid is vented to tank either via a bleed arrangement into the spring area or by a third stage of the valve whereby another aperture opens as the spring is compressed further beyond the normally shut position. When flow rates exceed about 12.5 GPM it is recommended that a pilot operated pressure reducing valve is used to handle the greater flow rates.

BLEED OIL PASSAGE

DIRECTLY CONTROLLED PRESSURE REDUCING VALVE SYMBOL

TO SECONDARY CIRCUIT PRESSURE SENSING LINE

EXCESS SECONDARY CIRCUIT PRESSURE FORCES SPOOL UP AGAINST SPRING

Figure 6.25

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MAINTENANCE: 5.3.3

PILOT OPERATED PRESSURE REDUCING VALVE.

Pilot operated reducing valves must be used for higher flow rates, since the increased spring force, with the increased displacement that would be required with a direct control reducing valve would make them impractical and have an adverse effect on performance. The valve comprises a pressure reducing valve and a pressure relief valve for pilot control. The pilot operated valve senses the secondary system pressure at the outlet port, and as long as the relief valve stays closed, pressures are equal above and below the main control spool. The light spring force holds the spool in a fully open position, and remains open until the secondary system pressure overcomes the spring setting of the relief valve. When the relief valve sense an increase in pressure above the set value, the relief valve opens relieving the pressure behind the spool to tank. The pressure imbalance on the spool cause the spool to be moved up because of the higher pressure acting on the front face. As the spool closes it restricts the opening that the fluid can flow through and in doing so reduces the pressure. When the pressure has been reduced to the set level on the relief valve, the valve closes The pressure behind and in front of the spool are now balanced and the spool will opened under the small force of the spring.

Figure 6.26

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MAINTENANCE: 5.4

DIRECTIONAL CONTROL VALVES

One of the most important advantages of hydraulics is the ease by which energy transfer can be made to occur. For example, once we extend a cylinder, we might want to redirect the flow of energy to retract the cylinder after it has performed its work. In the diagram below, simply by switching the control valve from one position to the other, we are able to effect cylinder extension and then retraction.

RETRACT

EXTEND

P

P

T

T

Figure 6.27.

Directional control valves are not only activated by solenoids. but also springs and mechanical cam rollers can be used to initiate control valve switching. The diagrams below show three methods of control valve switching. The valve on the top can be activated by the solenoid for one position and, when the solenoid de-activates, switching is done by the spring return. The diagram on the bottom shows a mechanical cam roller to switch one way and a spring return for the other direction. The drawing on the right shows a cutaway view of the cam roller.

SPRING

SOLENOID CAM ROLLER

CAM

ROLLER SPRING

Figure 6.28.

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MAINTENANCE: The working ports of the directional control valves are generally labelled with the letters 'A' and 'B' while the pressure and tank connections are labelled 'P' for Pressure and 'T' for Tank, respectively. The solenoids are generally labelled with lower case 'a' and lower case 'b' if there are two switching solenoids. These valves are often referred to in a "way-position" manner as shown below:

SWITCH POSITIONS ACTIVE PORTS 2/2 POSITION VALVE

A P

A 3/2 POSITION VALVE

P T

A 4/2 POSITION VALVE

B A6410129

P

T

Figure 6.29

NOTE! The number of ways in a valve refers to the number of active ports in each valve. The number of positions refers to the mode of each port with respect to the fluid (i.e. fluid flowing or blocked).

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MAINTENANCE: There are a large number of possible valve configurations. The diagrams below show various examples of way valves.

2 WAY VALVE

3 WAY VALVES

4 WAY VALVES

Figure 6.30.

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MAINTENANCE: The diagram shows the internal workings of the directional control valve and how it changes flow direction in response to various spool positions.

A B

P

T

A

P

T

B

Figure 6.31.

For example, if the spool were switched to the right, port 'B' would be connected to pressure and port 'A' would be connected to tank. If the spool were switched to the left, port 'A' would be connected to pressure and port 'B' would be connected to tank. If the valve was left in the middle position, all ports would be blocked. A large number of different flow directions may be produced from the same casing design by varying the spool design as shown in the figure 6.32 below.

A B

A B

P T

P T

A B

A B

P T

P T

A B

A B

P T

P T

Figure 6.32.

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MAINTENANCE: 5.4.1

PILOT OPERATED DIRECTIONAL CONTROL VALVES.

Because of their design, direct acting directional control valves are limited in their flow capacity. Sometimes it is necessary to use another four way valve, known as a pilot valve, to effect the switching of the main directional valve rather than just a solenoid. The pilot valve will be switched by the solenoid and then the pilot valve will cause the switching of the main directional control valve.

PILOT VALVE (SOLENOID ACTUATED)

A

B

T

B

P

A R

MAIN VALVE (PILOT ACTUATED)

A6411538 Figure 6.33.

The higher flow directional control valve is somewhat larger than a direct operated directional control valve; if it wasn't pilot operated, the solenoid actuator would have to be excessively large.

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MAINTENANCE: 5.5

PROPORTIONAL VALVES

Some solenoids simply switch on or off, other solenoids work on a principle of proportional force application. In response to a certain level of current, these solenoids apply an amount of force to cause a particular valve to move a distance proportional to the force. Generally, the valve spool is backed up by a light spring. The more current that is applied to the solenoid, the more force (and travel) is effected in the valve. In this way, we can control certain valve functions in a proportional manner. For example, in the diagram below, an analog output is sent to the appropriate valve driver card causing a current to be applied to the solenoid.

ANALOG OUTPUT

PA88 /PA89

K+

SOLENOID SIGNAL

KK VALVE (PRESSURE)

FEEDBACK SIGNAL TANK

Figure 6.34.

The above schematic shows an analog output to the driver card which then sends a particular current level to the solenoid of the K-valve. The signal is sent via the K+ and K- leads to the proportional solenoid. The other leads provide feedback of the valve spools actual position in order to correct errors in position.

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MAINTENANCE: 5.5.1

PROPORTIONAL PRESSURE CONTROL VALVE

The main system pressure control valve used on Engel machines is a proportional valve, referred to as the K-valve. As discussed in the last section, the force exerted by the solenoid can be increased or decreased simply by increasing or decreasing the current supplied to the solenoid, respectively. Therefore, an increase in current would cause the solenoid to exert more force against the spring, which would increase the relief pressure. The graph and the drawing below illustrate the above principle.

VALVE POPPET

CURRENT SOLENOID

PRESSURE SPRING TANK

RELIEF PRESSURE

Figure 6.35.

The input current produces a proportional deflection of the solenoid armature which acts on the valve poppet through a compression spring. The pressure on the poppet governs the oil pressure therefore the oil pressure is proportional to the input signal.

POSITION TRANSDUCER

VALVE POPPET VALVE SPRING VALVE SEAT

PROPORTIONAL SOLENOID

T

P

Figure 6.36

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MAINTENANCE: 5.5.2

PROPORTIONAL FLOW CONTROL VALVES

The position of the valve spool, which is acted upon by the solenoid, can be varied between a fullflow position and a no-flow position simply by increasing or decreasing the current supplied to the solenoid, respectively. The graph and drawing below illustrate this principle. (The drawing at the bottom of the page is a more accurate representation of an actual valve).

TO SYSTEM

CURRENT

SOLENOID

VALVE SPOOL

SPRING

FROM PUMP FLOW IN GPM

Figure 6.37.

The input current produces a proportional deflection of the solenoid armature which acts on the valve spool. The higher the current delivered to the solenoid, the higher the flow.

Figure 6.38.

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MAINTENANCE: 5.5.3

PROPORTIONAL SOLENOID WITH POSITION TRANSDUCER.

Speed and pressure are critical on Injection molding machines. For this reason, position transducers are used on proportional valves to guarantee that a set value of pressure, or speed is actually achieved, with minimal error. When the proportional solenoid receives a signal to move to a particular position, a certain amount of error is generated. For example, this error could be caused by friction in the moving part. The position transducer, is mounted on the end of the valve spool and sends a signal back to the amplifier corresponding to the actual position of the valve spool. The feedback signal (i.e. actual position) and the set value signal (i.e. set position), are compared electronically. A corrective signal will be sent to the solenoid if there was a difference between the set value and the feedback signal value. The position transducer is also known as a Linear Variable Differential Transformer (LVDT). The LVDT produces an electrical output proportional to the displacement of a separate movable core. PROPORTIONAL AMPLIFIER SET VALUE INPUT PRESSURE CONTROL LVDT

FLOW CONTROL

PROPORTIONAL SOLENOID

Figure 6.39

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MAINTENANCE: 5.5.4

PROPORTIONAL DIRECTIONAL CONTROL VALVES (PILOT OPERATED)

Pilot operated proportional directional valves are often (depending on machine size and options) used for improved control in the clamp circuits. The main stage is a modified directional valve with metering notches. The pilot valve moves through 4 positions and is controlled by a solenoid. Both the main spool and pilot spool positions are sensed by transducers. The feedback signal from the main spool is superimposed upon the pilot valve control circuit. This configuration helps to minimize or eliminate the effect of disturbances such as flow forces and friction at the main spool. The pilot valve meters oil flow to the main spool as it shifts between 3 operating positions when the solenoid is energized. When the solenoid is not energized oil pressure at the main spool is relieved and the centering springs cause the main spool to move to the center position. This is a fail-safe for Emergency off conditions.(Refer to symbol section of manual for hydraulic diagram).

DIRECTIONAL VALVE PILOT VALVE PILOT SPOOL POSITION TRANSDUCER

PILOT SPOOL

A

MAIN SPOOL POSITION TRANSDUCER

MAIN VALVE

MAIN SPOOL

Figure 6.40.

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MAINTENANCE: Two-stage proportional directional control valve

PILOT VALVE

A6411575

MAIN VALVE

CENTERING SPRINGS Figure 6.41.

5.6

OPEN LOOP VERSUS CLOSED LOOP (MOOG VALVE)

Some ENGEL machines are equipped with a "Moog" valve for precise injection speed, hold pressure and plasticizing control. In a closed loop system, feedback from the output is sensed, compared with the intended output, and if the two "values" are different corrective action is automatically taken by the appropriate electronic control circuit. The crucial difference between an open and closed loop is simply feedback. The actual output of the Moog valve is monitored and compared with the intended output. Whether the output, is measured by pressure and velocity transducers the data is fed back to be compared with the intended values. In this way, the injection pressure, hold pressure and plasticizing processes are precisely controlled in order to increase the probability of perfectly molded parts, every time.

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MAINTENANCE: 5.6.1

MOOG VALVES

Figure 6.42. Principle of Operation

An electrical command signal (setpoint UQS) is supplied to the integrated control amplifier which drives the pilot valve. The flow from the pilot valve moves the main spool. The position transducer measures the position of the main spool (actual value ULI) and produces a feedback voltage which is fed back to the control amplifier and compared with the command voltage. The control amplifier drives the pilot valve until the command voltage and feedback voltage are equal. The position of the main spool is proportional to the electrical command signal. To simplify matters, the spool position is taken as the flow rate command. The actual flow Qx depends on the electrical command UQS and the valve pressure drop DPx.

PILOT VALVE

NOZZLE FLAPPER NOZZLE

POSITION CONTROL AMPLIFIER

SPOOL POSITION TRANSDUCER

A6481578

Figure 6.43.

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MAINTENANCE: 5.6.2

TWO STAGE MOOG VALVE WITH CLOSED LOOP POSITION CONTROL

PILOT STAGE

STROKE TRANSDUCER MAIN STAGE

P

B

A

T

P

A6411579

External pilot oil connection with built-in rotary disk filter

PILOT STAGE

External pilot oil connection with built in tube filter Y

External pilot oil outlet to tank

X MAIN STAGE

T

A

P B STROKE TRANSDUCER Figure 6.44.

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MAINTENANCE: 5.6.3

THREE-STAGE MOOG VALVE WITH CLOSED LOOP POSITION CONTROL 1ST STAGE (torque motor with mechanical feedback )

2ND STAGE (with tube filter)

Y

SET VALUE U = + 10 V

COMPARATOR

ACTUAL VALUE

3RD STAGE

X

STROKE TRANDUCER

T

A

P

B

Figure 6.45.

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MAINTENANCE: 5.7

CARTRIDGE HYDRAULICS

Engel introduced cartridge technology into its hydraulic systems for the following reasons: • improved switching behavior • reduced piping • higher flow capabilities • multiple operating modes • reduced leakage • high reliability • fast operating times • more compact, easy to maintain The introduction of cartridge hydraulics has allowed for many complex valve functions to be achieved through a relatively small number of basic elements. Although the cartridges must be mounted in a custom manifold block, their simplicity solves many technological and economical hydraulic problems. The Components

Pilot valve

Cover plate X

Y

Ring Valve body Spring

B

A6410148

Valve poppet (or spool) Manifold block

A

Oil port

Figure 6.46.

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MAINTENANCE: Within the manifold block, many different control borings are possible. Examples of some of the possibilities are shown below. F

X

B

B

F

Y

B

X

F

A

Y

X

F

B

Y

B A

A

Y

B A

A

X

F

F

A

Figure 6.47.

The drawing of the cartridge below shows three separate areas for the pressure of the system to operate upon, A,B, or F. Depending on the pressure on F, A and B, the valve might be fully open, fully closed, or in some modulating position between fully open or closed.

AREA F=1.6

F

B

B A

AREA B=0.6

AREA A=1 Figure 6.48.

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MAINTENANCE: You will notice that area A=1, area B=.6 and area F=1.6, or area A plus area B equals area F. A force acting on area F would tend to seat the valve, while a force occurring at A or B could open the valve if area F was vented to tank. This valve type is mainly used for directional functions (open-closed function). A variant of the 1 : 0.6 : 1.6 cartridge valve is equipped with precision control notches and allows "soft opening and closing".(see diagrams, below left). Yet another variant has a connection from B to the spring chamber and together with a simple covering plate, with no bores, can be used as a check valve.(see diagrams, below right).

F

F

B

B A

A

PRECISION CONTROL NOTCHES

BORE

Figure 6.49.

In some situations, we use a cartridge valve with a 1:1 ratio. The diagram below shows two examples of this valve.

F

B

F

B

B

B

A

A Figure 6.50.

System pressure acts on the 'A' port only, and not the 'B' port. The 'B' port is reserved strictly for a tank connection. The valve on the left (i.e. with the nozzle) allows a small amount of flow from the 'A' port, through the cartridge, to the spring side. This has the effect of equalizing the pressure on both sides of the valve, cushioning its opening and closing.

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MAINTENANCE: To control pressure while hydraulic fluid is flowing through the valve, we employ a slide valve with an effective working ratio of 1:1. This type of cartridge valve is shown below and can be normally open (fluid flow) or normally closed (no fluid flow). F

F B B A

A

Figure 6.51.

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MAINTENANCE: The cartridge valve is inserted into the manifold and held in place by the cover plate. The cover plate provides the porting for the appropriate connections to the directional control valve.

b

a

c

X

X

X

A

B

A

B

A

B

P

T

P

T

P

T

P

A

T

X

F

Y

P

A

T

X

F

Y

DIRECTIONAL CONTROL VALVE

P

A

T

X

F

Y

COVER PLATE Y B

A

Y

X

Y

B

B

A

CARTRIDGE VALVE

A

ED91.641.7777E.P18

The diagram above shows three separate methods of controlling the pressure holding the valve closed. In both examples (a) and (b) the pressure applied to the top of the valve is acting on area 'F', a larger area compared to 'A', so the higher applied force will keep it closed. In (b), the pressure applied to the top of the valve is also acting on area 'F', a larger area compared to 'B', so again the higher applied force will keep it closed. In (c), the pressure applied to the top of the valve is also acting on area 'F', however this pressure comes from an external source (i.e. X pilot line). It is assumed that the pressure here is high enough to keep the valve closed. All three valves will open to their inlet pressure and flow if each respective directional control valve is activated. This will occur since the top area of the valve will be vented to tank and the only downward force will be the light spring. Example (a) shows flow going from 'A' to 'B'. Example (b) shows flow going from 'B' to 'A'. Example (c) shows flow as going either way.

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MAINTENANCE: Switching Time Influence

In order to limit pressure "spikes" at the valve during opening and closing, throttling orifices are used in the control lines. These orifices also cause a delay in valve response, the larger the orifice the less effect it will have on the valve. The diagram below shows three different throttling possibilities. The movement of the valve will be affected in the following manner: 14. will affect valve closing 15. will affect valve opening and closing 16. will affect valve opening

X A

B

P

T A

P

T

1 X

2

3 Y

F

Y

B

A

34

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MAINTENANCE: 5.8

CARTRIDGE VALVES EXAMPLE

The drawing below shows how a directional valve can be used to pilot a series of cartridge valves to control the extension and retraction of a cylinder. This figure is provided as an exercise to determine the sequence of events after the energization of either solenoid "a" or "b". Use a red pen to mark the pressure lines and blue pen to mark the tank lines.

P

T

a

b

C2

C1

C3

C4

P

T B

A

A6410135

The following two pages explain the circuit for extending and retracting the cylinder.

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MAINTENANCE: Extend the cylinder

P

T

a

C2

C1

b

C4

C3

P T B

A A6410135

PRESSURE TANK When Solenoid "a" is energized, pressure is connected to tops of cartridge valves 1 and 3 and the tops of cartridge valves 2 and 4 are connected to tank or zero pressure.

System pressure is applied to bottom of cartridge valves 2 and 3. Cartridge 3 valve is under pressure at top plus spring tension so the system pressure will not open the valve. Cartridge valve 2 is open to tank at the top and the pressure at the bottom will open that valve allowing pressure to point "A". Pressure at point "A" will extend the cylinder. Oil that is expelled from the cylinder will flow from point "B" to cartridge valves 3 and 4. Cartridge valve 3 is held closed by oil pressure at the top plus spring tension. Cartridge valve 4 is open to Tank at the top and the pressure from the oil being expelled will overcome the spring tension and lift the valve allowing oil to flow to tank.

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MAINTENANCE: Retract the cylinder

P

T

a

b

C1

C3

C2

C4

P T B

A A6410135

PRESSURE TANK When Solenoid "b" is energized, pressure is connected to tops of cartridge valves 2 and 4 and the tops of cartridge valves 1 and 3 are connected to tank or zero pressure. System pressure is applied to bottom of cartridge valves 2 and 3. Cartridge 2 valve is under pressure at top plus spring tension so the system pressure will not open the valve. Cartridge valve 3 is open to tank at the top and the pressure at the bottom will open that valve allowing pressure to point "B". Pressure at point B will retract the cylinder. Oil that is expelled from the cylinder will flow from point A to cartridge valves 1 and 2. Cartridge valve 2 is held closed by oil pressure at the top plus spring tension. Cartridge valve 1 is open to Tank at the top and the pressure from the oil being expelled will overcome the spring tension and lift the valve allowing oil to flow to tank.

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MAINTENANCE: 5.9

PRESSURE GAUGE.

All Engel machines are equipped with a pressure gauge to monitor various locations throughout the hydraulic system. Having this capability is invaluable to the operator or serviceman since knowing the pressure reading at a particular point is a clear indication of exactly how the machine is functioning. The gauge itself has six separate reading points numbered 1 to 6. By adjusting the indicator knob to the required position, the pressure occurring at that point in the hydraulic system can be read from the pressure gauge located in the center of the indicator knob. The specific point in the hydraulic system pertinent to each indicator knob position is clearly indicated on the hydraulic diagram supplied with each machine. It is important to note that when a pressure reading is not required, the gauge should be moved to a '0' position, located between each pressure position on the gauge. Adjusting the gauge to a '0' position relieves pressure from the working ports of the gauge. Failure to do so, could ultimately result in gauge malfunction.

0 3

4

0

0 150

100 1500

2000 2500

1000

2

5

50

3000

200

500

psi 0

0

A6410132

3500

bar

250

1

0

6 0

PRESSURE GAUGE IN BAR AND PSI Figure 6.52.

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MAINTENANCE: 5.10 HYDRAULIC ACCUMULATOR An Hydraulic Accumulator, is a steel tank which contains a rubber bladder pressurized with an inert gas, usually Nitrogen. Initial operation of the accumulator requires that the oil port be vented to atmosphere and the bladder charged with nitrogen. the charging causes the bladder to expand until it reaches the walls of the steel tank and closes the bladder protection valve, to prevent further expansion down the oil port. During operation, the accumulator within an hydraulic system allows fluid under excess pressure to enter the tank, compressing the bladder, the flow into the tank is damped by the nitrogen filled bladder. The fluid in the tank is now under pressure, from the compressed bladder, and at times of low pressure the fluid is returned to the system. Because of the relatively small mass and low friction properties of the bladder it can respond quickly to changes in system pressure. The properties of the accumulator offer several functions within an hydraulic system: • • • • •

Energy storage to aid pumps in systems with intermittent operation. In cases of pump failure, provides an emergency energy reserve. Shock and vibration absorber. Volume compensation in a system exposed to temperature and pressure changes. Compensation for fluid loss in a leaky system.

WARNING! DO NOT USE OXYGEN TO FILL BLADDER - OXYGEN + OIL = EXPLOSION! Before working on or putting accumulator off line, ensure pressure is at zero bar

Figure 6.53.

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MAINTENANCE: When the main machine hydraulic system is shut down the accumulator will automatically discharge. Check the accumulator pressure on the manometer selector switch / pressure meter, the pressure must be at zero bar. After the system has been shut down and when the accumulator is equipped with: • SAFETY AND SHUT-OFF MANIFOLD Close the main isolation valve first and then open the relief valve. • ACCU MANIFOLD Open the relief valve.

Figure 6.54 Accumulator Shut Off Lever.

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6. HYDRAULIC SYSTEM

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MAINTENANCE: 5.11 HYDRAULIC TROUBLESHOOTING Engel machines are fully tested before shipping to the customer and should provide long periods of trouble-free operation. The normal operation of the machine however, introduces wear into the system. Inevitably, parts do deteriorate over time and require servicing or replacement. Much time and effort has been invested developing an efficient hydraulic system design, care must be taken when replacing any separate component. Always replace components with the correct type or recommended alternative. All Engel machines are equipped with pressure gauges plugged into specific test points throughout the hydraulic system. This feature will aid in any hydraulic troubleshooting. An important prerequisite to effective troubleshooting, is to know the system and how it should function. All machine functions should be analyzed to understand how and why they work. When problems occur, it will be easier to understand why a particular function is not occurring and which component might be causing the problem. Excessive heat and/or noise are indications of trouble, and their cause should be investigated without delay.

NOTE! Over 60 % of all hydraulic problems can be directly or indirectly traced to dirt in the system.

System performance, efficiency and life are most greatly affected by three basic procedures, central to any preventive maintenance program. These are: 1.

Use clean hydraulic oil of correct grade and viscosity

2.

Have a regular program of changing filters, cleaning strainers and tank.

3.

Maintain tight connections to exclude air from being drawn into the system. Do not over tighten to the point of component distortion.

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MAINTENANCE: The following list includes samples of hydraulic problems, their likely cause and suggested solution. It is not a complete list, but an adequate guide to assist you in troubleshooting. PROBLEM

POSSIBLE CAUSE

SUGGESTED SOLUTION

Noisy Pump

Cavitation Housing leaking Suction line leaking Coupling miss-aligned

Pump starving for oil-filter? Check for tight connection, cracks Tighten clamp Align shafts

Noisy Motor

Coupling miss-alignment Coupling worn or damaged

Align shafts Replace or Repair

Noisy Relief Valve

Setting too low Setting too close to another relief valve

Increase pressure setting Increase pressure setting differential

Pump heated

Relief setting too high Relief valve defective Cavitation Worn or damaged pump

Adjust valve Inspect and/or replace Check filter and strainer Inspect and/or replace

Motor overheated

Relief setting too high Relief valve defective Excessive load

Adjust valve Inspect and/or replace Obstruction at outlet?

Relief Valve overheated

Valve setting incorrect Worn or damaged valve

Adjust valve Inspect and/or replace

Fluid overheated

System pressure too high Relief setting too high Incorrect fluid viscosity Cooling system defective

Monitor and adjust pressure Adjust valve Check viscosity rating Check for correct operation

No Flow

Fluid not getting to pump Pump drive coupling broken

Check inlet, filter, strainer Replace and check alignment Reverse rotation Check breakers Check for flow obstruction downstream Inspect and/or replace

Electric motor turning in wrong direction Electric motor not operating Entire flow passing over relief Pump damaged Low Flow

266

Flow control set too low Relief valve set too low Leak in system Flow valve defective Load sensing control on V.D. pump defective

6. HYDRAULIC SYSTEM

Adjust Adjust Inspect system and repair Inspect and/or replace Inspect and /or replace

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MAINTENANCE: PROBLEM

POSSIBLE CAUSE

SUGGESTED SOLUTION

Excessive Flow

Flow control set too high Load sensing control on V.D. pump defective Flow valve defective Improper size replacement pump

Adjust Inspect and /or replace Inspect and /or replace Replace with correct unit

No Pressure

No flow Defective K-valve

See "No flow" Inspect and/or replace

Low Pressure

Defective K-Valve Damaged cylinder Pressure reducing valve set too low

Inspect and/or replace Inspect seals and/or replace Inspect and/or adjust

Erratic Pressure

Air in fluid Worn relief valve Contamination in fluid Accumulator defective or lost nitrogen charge

Bleed air, check for leaks Inspect and/or replace Check fluid, filters, etc. Inspect and re-charge if necessary

Excessive Pressure

Pressure reducing valve maladjusted Load Sensing Control on V.D. pump defective

Inspect and/or replace

No Movement

No flow or pressure Mechanical bind No command signal to solenoid

See "no flow", "no pressure" Locate bind and repair Check signal sequence

Slow Movement

Low flow Fluid viscosity too high Worn or damaged cylinder Error in Amplifier signal

See "Low Flow" Check viscosity, temperature Check seals Check Amplifier output

Erratic Movement

Erratic pressure Air in fluid Erratic command signal Defective feedback transducer sticking flow valve

See "erratic pressure" Check for and repair leaks Adjust or replace amplifier Inspect and/or replace

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6. HYDRAULIC SYSTEM

Inspect and/or replace

Inspect and/or replace

267

MAINTENANCE: PROBLEM

POSSIBLE CAUSE

SUGGESTED SOLUTION

Valve Jams

Valve under stress Oil temperature too low Valve defective Dirt in system Incorrect oil type Solenoid defective Spring defective

Loosen screws and retighten Preheat system Inspect and/or replace Inspect and/or replace Check viscosity rating Inspect and/or replace Inspect and/or replace

Valve Flutters

Valve defective Pilot control defective Dirt in system Incorrect oil type

Inspect and/or replace Inspect and/or replace Inspect valve, clean system Check viscosity rating

Oil Dirty

System dirty Air filter defective Incorrect air filter

Clean tank, replace oil Inspect and/or replace Check requirements

Oil Foams

Air in oil Oil level too low Return line above oil level Incorrect oil type

Check for leaks Fill oil to level Extend return line Check oil requirements`

Water in Oil

Heat exchanger defective Fluid supply contaminated

Inspect and/or replace Check oil storage procedure

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MAINTENANCE: TROUBLESHOOTING EXERCISE

The diagram below shows a simple hydraulic system that has experienced a loss in pressure and speed. Any component could be at fault. Review the basic troubleshooting procedures that should be employed to determine the problem?

PRESSURE GAUGE

C

E F

A

B

D

BASIC HYDRAULIC SYSTEM = MECHANICAL CONNECTION

1. Suction Filter?

clogged. check for damage and clean the strainer. check for leaks at point A.

2. Pump or Relief Valve?

disconnect at points B and C, run the pump against the relief valve. observe the flow at point B. if the pump is faulty, the flow will decrease as the relief setting is increased. if the pump is not faulty, inspect the relief valve for correct operation, check for blockages, spool binding, spring operation, etc.

3. Cylinder?

extend the cylinder and leave it under pressure. disconnect at point E and check for any significant leakage. retract the cylinder and leave it under pressure. disconnect at point F and check for any significant leakage.

4. Directional Control Valve?

disconnect at points D,E and F. plug E and F. switch to working positions and check for leakage at point D.

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MAINTENANCE:

270

6. HYDRAULIC SYSTEM

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MAINTENANCE: 7. ELECTRICAL SYSTEM.

Main Power

Transformer Main-240V

Electric Motor

Transformer 240V-120V

Motor Start CON 115

Heat CON 129

Moldheight Motor

Lubrication Motor

240V-24VDC Power Supply

240V Receptacle

Heat Card Supply

Analog Card Supply

ECG Card Supply

24VE Switch Supply

24VK Digout Supply

24VR SSR Supply (triac)

Power Supply CON 117

Emerg. Stop

Moldheight CON 124,125

Receptacles 120VAC

CON 120

VE,VK,VR CON 136

Fans & Lights

Card Rack Power Supply

Digin Card Supply

Monitor

Figure 7.1 Electrical Block diagram

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MAINTENANCE: 1.

ELECTRICAL SYSTEM OVERVIEW.

Three phase power is supplied to the injection molding machine at between 575 / 460 Volts AC, this supplies the main induction motor which drives the hydraulic pump for operating the system hydraulics. The three phase supply is stepped down by an auto transformer to 230 Volts AC to supply the Mold Height Motor, Lubrication Motor, Card Rack Power Supply and Barrel Heaters. The 230 AC volts is stepped down to 115 volts AC to supply the Contactor and Relay coils, Indicator Lights, Fans, Hour Meter and Machine Alarm. Various electrical outlets receptacles are provided at all the different voltage levels according to individual requirements, the standard locations are shown on figure 7.13. Two electrical outlets receptacles are always fitted, one at 230 VAC for the external disk drive and one at 115VAC for the printer. Operating the main switch, on the cabinet, applies power to the step-down auto transformer which is dropped to 230 Volts and supplies the 230/115 Volt step-down transformer which is required to operate the contactor coils. With the "Control Voltage" switch in the ON position the following facilities are enabled: 1. Electrical cabinet cooling fan. 2. Electronic cabinet cooling fans. 3. Hours run meter. 4. Card Rack 24 Volt dc power supply. With the 24Volt dc power supply enabled the following facilities are available: 1. Operation of the mold Height Motor. 2. Operation of Main Motor Enable relay. 3. Operation of Lubrication Pump. 4. Operation of Barrel Heaters. 5. Operation of Gate Closed relay. 6. Machine alarm. If the following conditions are satisfied the "Motor Start" switch can be operated to "START" and the main motor will start. 1. Emergency Stop push-button is set (if the button is pushed in, twist it to release). 2. Control Voltage switch on panel is set to ON. 3. Non Operator side safety gate is closed, limit switch E3 is held closed and E4 is not operated. 4. Operator side safety gate is closed, limit switch E1 is held closed and E2 is not operated. 5. Gate Closed relay (CRE) is energized. 6. Mode Select switch is set to MANUAL. 7. Motor Enable relay is energized. If any one of the above conditions is not met, the motor will not start.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: If the motor is running, opening any of the safety gates, pushing in the emergency stop button, turning off the Control voltage switch or if the Main motor thermal overload trips the motor will stop. Check all the conditions exist if the motor will not run or the motor stops for an unknown reason. If the Mold height motor will not run check that the following conditions exist: 1. Limit switch E22 and E23 are closed.

NOTE!

2. 3. 4. 5.

3

If either limit switch is open the mold height adjustment has reached the limit of adjustment. CRFG relay is energized. CRFK relay is energized. Both mold Height contactors are initially de-energized. Varistors across contactor coils are not short circuit.

φ

3

φ

M MAIN HYDRAULIC MOTOR

3 PHASE MAINS 230V 3

φ

3

φ

3

φ

M

MOLD HEIGHT MOTOR

M

LUBRICATION MOTOR

230VAC / 24Vdc

ELECTRONIC CONTROL

POWER SUPPLY 3

φ

1

φ

230V

120V SWITCHGEAR

HEATER CONTROL

HEATERS

Figure 7.2 Simplified Electrical Circuit Diagram

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MAINTENANCE: 1.1

HOW TO READ THE ENGEL ELECTRICAL SCHEMATICS

Each electrical schematic page has a page number (PG#1) located at the bottom right of the title block. The total number of pages in the document is also given in this area. Each page has up to 96 line numbers, the number incorporates the page number and line number (e.g. 101 - 196). Components are identified by their location within the:• drawing package • physical location on the Injection Molding machine • location on the page • type of component For example =ELE+6CL-515CR is a control relay (CR) found on page 5, line 15 (515) and is physically located on the operator side of the injection base on the cabinet liner (+6CL). the drawings can be found in the electrical section of the drawing package (=ELE). Drawing packages: ELE = Electrical 1.1.1

PNE = Pneumatic

PHYSICAL LOCATION NAMING CONVENTION

Example: +1MC

+ = Physical location 1 = Clamp base - Non Operator side M = Manifold C = Clamp

First Character

Second Character

Third Character

274

HYD = Hydraulic

1= 2= 3= 4= 5= 6= 7= 8= 9= 10 = 11 = 12 = B= M= C= A= A= B= C= E= H= I= L= P= R=

The physical location of the item is the clamp manifold on the operator side of the clamp base

Clamp base - Non operator side Clamp base - Operator side Stationary platen - Non operator side Stationary platen - Operator side Injection base - Non operator Injection base - Operator Main injection unit Injection unit parallel to main injection unit Injection unit 90o to main injection unit (horizontal) Injection unit 90o to main injection unit (vertical) Injection unit 45o to main injection unit (vertical) Clamp unit Box Manifold Cabinet Auxilliary device Accumulator Box “B” Clamp Ejector Heat Injection Liner Push button panel Control rack

7. ELECTRICAL SYSTEM.

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MAINTENANCE: 1.1.2

ELECTRICAL LINE TYPES

Line Type

Function

Solid

Electrical power AC and d.c.

Dash, dot

Grouding

1.1.3

501 502 I 547 578 1.1.4

PAGE AND LINE NUMBERING

Page and line number to identify component. The last two numbers identify the line number. The number(s) before the last two, identify the page number. For example: -515CR is found on page five, line 15 and is a Control relay TYPICAL EXAMPLES EXPLAINED

Represents the engineering chapter that determines the device name Represents the physical location of the component Represents the page and line location of the component within the document package Represents the type of component being identified (CR = Control relay) Function of relay (software designation)

Child symbol (device identification is determined by parent) Components that have the same device identifcation, are linked together throughout the documentation package. Parent symbol Page and line number is used for device identification

Cross reference symbol shows page and line reference for child symbols associated with parent. The control relay is on line15 of page 5 and the contact associated with that relay is on line 5 of page 5. Function of relay (software designation)

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MAINTENANCE: Cable core designation. Cable names consist of the prefix “W” which is followed by the page and rung numbers of the first core used.

Example: Quick disconnect plug controlled by the electrical chapter, physically placed in location 4. 18501PL represents a pin chart drawn on page 185 line 01

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: Table 7.2 Commonly used electrical symbols

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MAINTENANCE: NORMALLY CLOSED PUSHBUTTON

NORMALLY OPEN PUSHBUTTON

NORMALLY OPEN SWITCH

NORMALLY CLOSED SWITCH

NORMALLY OPEN CONTACT

NORMALLY CLOSED CONTACT

HEAVY DUTY CONTACT

CONTACT BREAKER WITH THERMAL OVERLOAD TRIP

THERMAL OVERLOAD TRIP

NORMALLY OPEN LIMIT SWITCH

NORMALLY CLOSED LIMIT SWITCH

NORMALLY OPEN LIMIT SWITCH HELD CLOSED

NORMALLY CLOSED LIMIT SWITCH HELD OPEN

PROXIMITY SWITCH

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MAINTENANCE:

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MAINTENANCE: 2

THREE PHASE INDUCTION MOTORS.

The majority of induction motors used on Engel machines are of the squirrel cage rotor type, which are highly efficient and run at an almost constant speed under normal load conditions. The squirrel cage motor consists of two main parts: 1. Stator. 2. Squirrel cage rotor. Stator.

The stator consists of a fixed steel laminated frame with slots arranged radially around the inside, into these slots three coils are wound alternatively and are set 120o apart. The ends of the windings are brought out to a terminal box to be connected to the mains supply. Rotor.

The rotor consists of solid copper bars arranged in a drum shape and short circuited at each end with a copper ring. The conductors are lightly insulated and placed in slots in the laminated iron core. This type of rotor has no external connections, which eliminates the need for slip rings and brushes, and that makes for a cheap and reliable motor. Operation.

The three phase induction motor operates on the principle of a rotating magnetic field, each phase current flowing in a phase coil induces a magnetic field which varies sinusoidally in intensity as the current varies, as one phase reaches a peak, the other phases will be at some lesser value and in opposition to the first. As each phase in turn reaches a maximum value and the other two are reduced in value, a rotating magnetic field is set up which is equal to the frequency of the electrical supply. The R.P.M. or Synchronous speed of the field can be found using the formula: Ns = 60 f /p

where:

eg.:

280

Ns f p

= = =

synchronous speed of the field. frequency of the supply. the number of pairs of poles. Multiply by 60 to convert to minutes.

Ns

=

60 x 60 / 1

Ns

=

3600 / 1

Ns

=

3600 r.p.m.

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MAINTENANCE: If each phase coils where split up so that there were effectively two coils wound at 90o from each other, the machine would be said to have four poles. As seen previously the number of poles determines the synchronous speed of the motor. Four pole machine

Ns

Eight pole machine

=

60 x 60 / 2

Ns

=

60 x 60 / 4

=

3600 / 2

Ns

=

3600 / 4

=

1800 r.p.m.

Ns

=

900 r.p.m.

Torque or turning motion.

The rotating stator field induces an E.M.F. in the rotor conductor which in turn produces torque that turns the rotor in the same direction as the field. The direction of the magnetic flux is from the stator to the rotor, and an E.M.F. will be induced in the rotor conductor. The current flowing in the conductor will produce a magnetic field around that conductor. The field of the conductor will react with the field from the stator, strengthening the field on one side and weakening the field on the other. The stronger field will push the conductor towards the weaker side, similar forces will be applied to all the conductors on the rotor producing torque and causing the rotor to rotate. If the rotor reached synchronous speed, then there would be no relative motion between the rotor and stator, a null would have been reached where there was no torque applied to the rotor. So therefore the rotor can never quite reach the speed of the stator field, this difference between the two speeds is called "slip". Slip may range from 2 - 5% of the synchronous speed, i.e. for a four pole machine the slip may be between 36 and 90 R.P.M. depending upon the size of the machine. Bigger machines usually produce less slip. Starting torque is usually low for squirrel cage rotor machine, this usually caused by design as a low resistance rotor makes for a more efficient machine with less slip, but less slip means lower torque. Conversely increasing rotor resistance increase torque and slip and therefore is a lee efficient machine, commonly these types of machines are started off load or with very light load. Starting an Induction motor.

Initially at start the motor acts like a transformer with a short circuited secondary, so the starting current may be anything up to five times the normal full load current. The majority of motors employed by Engel use the direct-on -line start, where the motor is connected directly to the mains supply. Starting currents are high and may cause interference to other users.

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MAINTENANCE: THREE PHASE SUPPLY

CONTACTOR

START

STOP

OVERLOAD COILS OL TRIP A

INDUCTION MOTOR

Figure 7.3 Direct on line starting.

More powerful motors of 40 HP. and above running on 230 V AC or 208 V AC, use WYE - DELTA starting. This method employs the six connections to the three stator windings, which are all brought out to the starter contactor.

RUN

c

b

S U P P L Y START

A

B

MOTOR

a c

b

a

C

B

A

C

Figure 7.4 WYE - DELTA Starting.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: For normal running the windings are connected in DELTA, but for starting they are connected in WYE. This reduces the starting voltage per phase to 58% ( or 1 over the square root of 3) of the running voltage. The change over from WYE starting to DELTA running is made by a double throw switch with interlocks to prevent starting from the run position. Squirrel cage induction motors are highly efficient and an almost constant speed machine under normal running conditions, but has poor starting torque and must be start off load or with a very light load. Supply voltage variations must be kept to a minimum as a small drop in voltage can seriously effect the torque output of the motor. Induction Motor Tests.

Keeping a record of the normal load current in each phase, ideally the currents should all be the same, taken periodically is a good indicator of impending problems or deterioration of the motor. Two tests can be made to determine if an induction motor is serviceable: Continuity.

Continuity of the phase windings must be performed with the mains supply off and locked out and the leads to the motor disconnected. The test can be performed using a continuity tester or an accurate resistance meter. Insulation.

Use a "Megger" insulation tester of at least 500 Volts, 1000 Volts would be better if available, to check for any insulation breakdown that may occur when the motor is subjected to high voltage. Insulation test between each winding and the metal motor casing and between each phase winding should give a reading of at least 1 M W for ambient temperatures up to 40oC and at altitudes of up to 3000 feet. A reading of less than 500 KW will indicate an insulation breakdown. Motor Maintenance.

The grease nipple and grease relief are mounted at each end of the machine in the bearing housings to lubricate the shaft ball or roller bearings.

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MAINTENANCE: Table 7.3 Trouble shooting Induction Motors.

PROBLEM

CAUSE

POSSIBLE SOLUTION

Motor will not start

Overload tripped

Wait for overload to cool try stating motor again, if "no go" check the following.

Power connected?

Connect

Open circuit stator or rotor

Check with continuity tester.

Short circuit stator

Check with ammeter for balanced phase currents.

Loose connections

Tighten connections

Winding grounded

Check between windings and ground with a Megger or other insulation tester.

Too much load

Disconnect load, and try again.

Wrong connections

Reconnect

Incorrect supply volts

Check nameplate, ensure motor voltage requirement is matched to supply voltage.

Motor single phasing

Stop motor try to restart (motor will not start single phase) check windings as before

Vibration

Disconnect load and try motor again if still noisy motor needs to be re balanced

Air gap not uniform

Possible new bearing required.

Noisy ball bearing

Grease or replace

Object caught in fan

Check fan end cover and remove any debris or foreign objects.

Motor loose on foundations

Tighten motor mounting bolts

Motor overloaded

Check load current with ammeter, if current is greater than rated full load current reduce load.

Restricted ventilation

Clean air passages and remove any obstructions.

Incorrect voltage supply

Check nameplate, ensure motor voltage requirement is matched to supply voltage.

Stator shorted or grounded

check as before

Motor noisy

Motor running temperature too high

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MAINTENANCE: 3.

MOLD HEIGHT MOTOR.

The Mold Height Motor is a three phase induction motor equipped with helical gearbox for slow running applications. The Mold Height motor is connected up to run in both directions, to allow mold height to be increased or decreased. The reverse motor function is achieved when the "decrease" switch is operated, two of the three phase windings are reversed by the "decrease " contactor. The Mold Height Motor Unit has a 24 Volt dc operated brake to give the motor a positive stop when adjusting the mold height. The dc brake circuit is protected from back EMF by a diode across the dc coil. As the brake is switched off the collapsing dc field will generate a voltage spike of several hundred volts, which will cause arcing at the nearest set of open contacts, the diode causes the back EMF to flow in the coil and the energy is dissipated as heat. The speed reducing units are sealed to prevent oil leakage and also the ingress of moisture and dust. The units are either fitted with one oil filler plug or on larger models a filler/level and drain plugs.

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MAINTENANCE: 4.

TRANSFORMERS.

Single phase transformer.

A simple single phase transformer consists of two windings, primary and secondary, electrically insulated from each other but wound on a common laminated core. MAGNETIC FLUX

LOAD

SUPPLY

SIMPLE TRANSFORMER

Figure 7.5

The Primary and Secondary windings are usually wound on the same limb to minimize magnetic leakage. The alternating current (AC) supply produces an alternating magnetic flux in the iron core, the alternating flux induces the same electromotive force (E.M.F.) in each turn of the secondary windings. The secondary voltage output will be dependent upon the number of turns in the secondary coil, for all practical purposes the voltage ratio of the transformer is equal to the turns ratio. If the primary coil has twice as many turns as the secondary coil, the transformer has a turns ratio of 2:1 and the output voltage will be half of the input voltage. Three Phase Transformers.

The three phase transformer is similar to the single phase version, except that it has three sets of windings on three limbs. The three phase voltages have a 120o phase difference from each other and therefore the three secondary voltage outputs will be a ratio of these phase displaced voltages. The secondary voltage output on a particular limb will be in phase with the primary on that limb. The primary and secondary windings can be connected in either WYE or DELTA depending upon the application required. The most common configuration is DELTA - WYE, the secondary WYE provides a neutral point which can be grounded, and will supply both balanced and unbalanced loads.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: SECONDARY - WYE

NEUTRAL

PRIMARY - DELTA THREE PHASE TRANSFORMER

SECONDARY - WYE

NEUTRAL PRIMARY - DELTA

Figure 7.6 Three phase transformer. Auto Transformers.

The auto transformer has only one winding for both primary and secondary, the secondary is supplied by means of taps off the primary. Auto transformers are ideal for providing a small raising or lowering of the input voltage, they are smaller and cheaper than the double wound transformer because they only have one coil. Auto transformers do not provide the electrical isolation of a double wound transformer and any fault on the auto transformer could cause the full primary voltage to be applied to the secondary circuit. However auto transformers are ideal where a small difference in voltage is require, and the savings in weight and cost can be quite considerable, in practice the transformer ratio used is never greater than 3:1.

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MAINTENANCE: Figure 7.7 shows a single phase auto transformer representation, a three phase version would just be three of the windings shown connected in either WYE or DELTA configuration.

OUTPUT VOLTAGE LESS THAN INPUT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE GREATER THAN INPUT VOLTAGE

Figure 7.7 Single phase auto transformer Transformer tests.

Continuity of the windings; this test must be performed with the mains supply off and locked out and the leads to the transformer disconnected. The test can be performed using a continuity tester or an accurate resistance meter. The resistance of each winding should be approximately the same. Use a "Megger" insulation tester of at least 500 Volts, 1000 Volts would be better if available, to check for any insulation breakdown that may occur when the transformer is subjected to high voltage. Insulation test between each winding and the metal casing and between each phase winding should give a reading of at least 1 M W for ambient temperatures up to 40oC and at altitudes of up to 3000 feet. A reading of less than 500 KW would indicate an insulation breakdown. Transformer maintenance.

Check that all electrical connections are tight. Heat discoloration around the terminals indicates the possibility of a loose connection.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: 5.

CARD RACK POWER SUPPLY UNIT.

Three phase transformer, with four primary taps and three sets of smoothed dc output. The four primary taps are provided to be able to select a suitable tap to give the required output of between 28 and 32 Volts dc.

+

+

28 TO 32 VOLTS 2 AMPS

+ +

+

28 TO 32 VOLTS 18 AMPS

-

+

-

+

+ +

SECONDARY TRANSFORMER WINDINGS

28 TO 32 VOLTS 5 AMPS

Figure 7.8 Card Rack Power Supply.

Figure 7.8 shows the secondary side of the card rack power supply, the transformer output on each phase is 27 Volts AC and the three windings are rated at 2, 5 and 18 Amps. The AC voltages are full wave rectified and smoothed by the large reservoir capacitor and a small capacitor to eliminated most of the AC ripple associated with producing dc voltages from AC. The smoothing and full wave rectification also has the effect of raising the dc voltage above that of the AC for a voltage of 27 Volts AC the dc voltage will be approximately 32. The primary input tap best suited to give an output voltage of between 28 and 32 volts dc should be chosen.

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MAINTENANCE:

NOTE! Ensure that the power is isolated from the transformer before changing taps.

6.

RELAYS.

The relays used on the injection molding machine are either 115 VAC or 24 V dc operated and are designated on the machine electrical drawings by CR or CRXX depending upon the application. The relays are usually enclosed in a clear plastic case and oriented in such a manner that the contacts can be seen, this enables the maintenance personnel to observe the relay contacts to determine whether the relay is energized or not. The 24 Volt d.c. relays are four pole double throw and have a coil resistance of approximately 165 Ω, using a good quality, high impedance multimeter this value can be checked to determine the serviceability of the relay. If the coil operating voltage is measured across the coil connections but the relay is not energized, substitute the suspect relay for a known operational one of the same type to prove if the relay is faulty or not.

7.

SOLID STATE RELAYS.

Solid State Relays are usually single pole devices with a response time in the microsecond range because they are a semiconductor device with no moving parts. The Solid State Relays have the ability to switch high currents up to 90 amps at voltages of up 480 VAC. Two possible types of SSR's are be used in the control of the barrel heaters: 9. Triac (Bi-directional Thyristor). 10. SCR (Silicon Control Rectifier). The four pin package contains basically the components shown in figure 7.9 or 7.10 and on the injection molding machine barrel heater control application usually have a varistor mounted in parallel with the Triac to protect it from transient spikes. The Triac at the heart of the SSR is a three terminal bi-directional device which blocks current flow in both directions in it's "off" state, until it is triggered by a gate signal, when it conducts in either direction. The triggering input is a dc. voltage of 3 to 32 volts derived from the Heat Control Card E7.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE:

CURRENT LIMITER TRIAC

PHOTO DEVICE

LOAD

TRIGGER

L.E.D.

VARISTOR

Figure 7.9 Triac Solid State Relay

The SCR is similar to a diode in that when the gate is triggered it will only conduct one way and blocks the other, before the gate is triggered the SCR will block in both directions. As with the Triac the gate requires between 3 to 32 Volts dc. to trigger the device. In the Figure 7.10 two SCR's are connected in parallel to provide the function of conducting in both directions, this combination is most commonly used for A.C. switching as the SCR is less sensitive to internal gate triggering sometimes experienced by the Triac.

CURRENT LIMITER PHOTO DEVICE

L.E.D.

LOAD

TRIGGER

SCR

VARISTOR

Figure 7.10 Thyristor Solid State Relay

Both configurations have an internal RC network and an external varistor, the RC network serves to reduce the possibility of internal triggering of the gate and also provides transient suppression . Transients and electrical noise can often effect the optical receiver transistor and the RC network proves most effective in providing immunity in this area. The varistor also provides protection from transient spikes and serves to protect the Triac or SCR from prolonged transients or pulse train that would overwhelm the RC network.

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MAINTENANCE: 8.

VARISTORS.

Varistors (Voltage Dependent Resistors) are used to protect electrical components, that are sensitive to voltage overloads, from voltage spikes. At normal operating voltage the varistor's impedance is so high that only a few micro - amperes will flow through it. As a voltage of either polarity approaches the varistor's clamping voltage, the varistor rapidly becomes a low impedance diverting the current spike associated with the voltage spike through the varistor thereby protecting the component. Varistor will usually fail to a short circuit, failure however is a good indication that a higher energy device is required for that particular application. In failing to a short circuit the varistor will protect the Triac or SCR and control of the heater circuit will be lost. SPIKE SUPRESSORS

The Spike Suppressors are located with the Mold Height Motor and Lubrication Motor and are a three phase version of the transient suppression found with the Solid State relays. The RC network filters the electrical noise and random transients and the varistor or suppressor absorbs the transient energy above a certain level thereby sharing the transient with the load, which in this case is the motor windings. The figure shows both symbols for transient suppressors.

SUPPRESSORS

Figure 7.11.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: 9.

SOLENOID OPERATION

A solenoid is an electromagnetic coil with movable ferrous core. The core is attracted into the coil by the force of magnetism when the surrounding coil is energized. The core moves against the force of a spring which will return the core to a relaxed position when the voltage is removed. The position of the core can be varied by varying the voltage across the coil, this property is used to vary the position of proportional valve spools as discussed in chapter 6 paragraph 12. The solenoid is an important component of our machines and many of the hydraulic controls depend on their switching. Whenever current flows through a wire, a magnetic field is created around the wire. The magnetic field can be strengthened in the following ways: 17. Increasing the voltage to the solenoid 18. When the wire is wound into a coil, the magnetic field becomes stronger and "lines of magnetic force" are generated at 90o to the coil.

N

THE HIGHER THE NUMBER OF TURNS , THE HIGHER THE MAGNETIC FIELD

S 8.

A magnetic field flows more easily through a metal than through air, if the coil is wound around a magnetic medium (iron former), the magnetic field will be strengthened.

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MAINTENANCE: 10.

DC SOLENOIDS

The solenoids employed on Engel Injection Molding Machines are DC solenoids and they switch the Hydraulic Control Valve connections between tank and pressure. When a d.c. current is applied to the coil, the armature is attracted by the magnetism into the coil against a spring force. When the current is switched off the armature returns to it's relaxed position aided by the spring.

ELECTRICAL CONNECTOR ACTUATOR

LED INDICATOR

ARMATURE

COIL

SPRING

Figure 7.12 Main components of a solenoid.

Energizing the coil causes the armature to move in the direction of the arrow, which moves the actuator which in turn changes the position of Hydraulic Directional Control Valve spool from one state to another. The solenoid is essentially a switch, that switches or not depending on whether or not a d.c. current has been applied to the coil of the solenoid. The Hydraulic Control valve can have a solenoid at each end to move the valve from the central position to either right or left position depending on the function required.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: 11.

FANS.

The electrical cabinet has two 120 Volt fans, one on the right hand side of the cabinet and one on the left hand door of the cabinet, bringing air into the cabinet through filters and exhausting the air through an outlet filter on the left hand side of the cabinet. The filters must be cleaned monthly, in a warm soap solution, rinsed in clean water and allowed to dry before replacing with the soft side away from the fan. The louvred retaining covers for the filters snap in and out by hand.

12.

RECEPTACLES.

12.1 460 VOLT. 460 Volt outlet receptacles are provided at various locations on the machine (see figure 7.13).

12.2 230 VOLT. 230 Volt outlet receptacles are provided at various locations on the machine (see figure 7.13).

12.3

120 VOLT.

120 Volt outlet receptacles are provided at various locations on the machine (see figure 7.13).

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MAINTENANCE: STANDARD LOCATIONS FOR OPTIONAL ELECTRICAL POWER OUTLETS ES 125 TO ES 400

B

G

C

E H

I

A

B

G

C

Location codes A Outer leg, Clamp end, Non operator side B Outer leg, Clamp end, Operator side C Electrical cabinet, left end, Operator side E Electrical cabinet, right end, Operator side F * Heater box, Injection end, Non operator side G Inner leg, Clamp end, Operator side H Hydraulic cover end plate, Non operator side I Inner leg, clamp end, Non operator side * If option installed ES 125 TO ES400 Figure 7.13

296

F

7. ELECTRICAL SYSTEM.

E

Max. No. of Receptacles 4 4 4 4 4 4 2 4

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MAINTENANCE: 13

TRANSDUCERS.

A transducer is a device which measures a particular energy input and produces an electrical output that is proportional to the input. Engel machines use transducers to measure: • Force • Hydraulic pressure • Cavity pressure • Flow rate • Velocity • Position • Heat Before reviewing the various types of transducers used on Engel machines, it would be useful to explain our transducer selection criteria. Linearity.

It is important that the output is linear over the operating range of the transducer, that is to say that the output is proportional to the input, e.g. if the input is doubled the output is doubled.

Repeatability The transducer output should be identical to a previously measured output if the inputs from both measurements are identical. For example, if a measurement of heat is taken twice and the temperature has not changed, then both readings should be identical. Resolution.

The ability to respond to small changes in the input, or the amount of input required to produce a change in output. If the transducer is unable to respond to small changes in input, then its resolution is said to be poor.

Speed.

If a transducer is incapable of responding quickly to changes in input, the delay involved would cause the system to be less responsive and less stable.

Range.

The range of the transducer is its ability to react to the full extent of the phenomena it is trying to monitor. It should be capable of measuring the full operating range of the particular variable it is measuring.

Offset.

The offset refers to the amount of output for zero input. The ideal would be to have an electrical output of zero when the variable being measured is at its zero position.

Durability.

This is a measure of the lifetime of the transducer. The transducer's useful life might be shorter than its physical life.

Signal Form. An AC transducer will not respond correctly to a DC input, and visa versa. Cost.

All of the above factors must be weighed against the cost of the transducer. In some cases, cost may turn out to be the most important factor.

Transmitters

Transducers generate a signal that is proportional to the variable that is being monitored, but in some cases the signal is too weak to be easily measured and acted upon by the electronic control system. Also, since the signal is relatively weak, it could easily be influenced by magnetic or electrical interference in the area. Therefore, these transducer signals must be amplified to a level

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7. ELECTRICAL SYSTEM.

297

MAINTENANCE: that is more useful to the electronic control system before being transmitted. For example, the mold cavity pressure transducer sends out a signal to an amplifier unit (SG-1 or QV - 10), which then transmits to the analog card, an amplified signal of approximately 5 mV/bar. This is a value which can easily be monitored and acted upon by the control system.

13.1 STROKE TRANSDUCERS Stroke transducers are used to monitor the actual position of the mold, the screw, the nozzle, and the ejector. ANALOG CARD

STROKE TRANSDUCER 2

SCREEN 1

0 VOLTS

2

P

1

3

PLUNGER ROD

3

+10 VOLTS

7.14 Simplified Representation of a Stroke Transducer.

The stroke transducer is a potentiometer, and as the position of the plunger rod (wiper) changes, so the voltage across terminals 1 and 2 changes. The + 10 Volts reference voltage is applied across terminals 1 and 3.

NOTE! Care must be a taken to connect leads 1 and 3 correctly when a stroke transducer is being replaced. If these two leads are interchanged, the signal sent back to the electronic control unit will be in error and will "confuse" the machine. It will "think" it is in one position (fully extended), when it is really in the opposite position (fully retracted).

Mold Stroke.

As the mold closes, the stroke transducer extends but the output voltage on terminal 2 decreases. In this case the leads to terminals 1 and 3 have been interchanged because the transducer extends with mold closing, but when the mold is closed the output from the transducer must be near zero indicating a minimum position.

Ejector Stroke.

As the ejector moves forward, the stroke transducer extends and the output voltage on terminal 2 increases.

Nozzle Stroke.

As the nozzle moves back, the stroke transducer extends and the output voltage on terminal 2 increases.

Screw Stroke.

As the screw moves back, the stroke transducer extends and the output voltage on terminal 2 increases.*

298

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: (* Machines 125 Ton and up: As the screw moves back, the stroke transducer retracts and the output voltage on terminal 2 increases.) If a new transducer has been installed and appears to be operating in reverse, transpose leads 1 and 3 at the terminal strip or on the Analog card.

13.2 CLAMP FORCE STROKE TRANSDUCER (LVDT) The clamp force transducer measures the tonnage value when the clamp closes. When the clamp closes the compression force causes the tie-rods to stretch. The function of the clamp force transducer is to measure the amount of tie-rod stretch. Engel machines use an LVDT (linear variable differential transformer), which is connected to a movable rod inserted into one of the tie-rods. Based on the amount of stretch, a specific electrical feedback signal is sent back to the electrical control unit. The LVDT signal is amplified so that the electronic control unit receives a signal of approximately 1.2 mV/0.01 of a millimetre (1/100,000 of a metre) of stretch. Typically, the amount of stretch is in the range of between 0.35 of a millimetre and 1 millimetre, depending on the clamp force of the particular machine. The working range of the transducer feedback signal is between 50mV at a minimum and 500mV at a maximum. INDUCTIVE TRANSDUCER (LVDT)

TRANSDUCER PIN

TRANSDUCER HOUSING

CABLE CONNECTION

MOVABLE ROD

TIE-BAR

DISC SPRINGS

LOCK NUT (fine adjustment)

LOCK NUT (coarse adjustment) CABLE SHEILD

A N A L O G

C A R D

SCREEN SK1 0V SK3 + SK4 SK2 +5V

With reference to figure 7-15, as clamp forces are increased, the tie rod will stretch. As the tie-rod stretches, the disc springs will tend to keep the movable rod at the bottom of the hole in the tiebar. The plunger of the LVDT is screwed onto the movable rod and will move with it as clamp force increases. For every 0.01 of a millimetre of plunger movement inside the LVDT, an amplified signal of approximately 1.2mV is detected at the electronic control unit.

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7. ELECTRICAL SYSTEM.

299

MAINTENANCE: 13.3 HYDRAULIC AND MOLD CAVITY PRESSURE TRANSDUCERS To measure pressure, Engel uses either a quartz piezoelectric transducer or a strain gauge transducer. Generally, the piezoelectric transducer is used for cavity pressure and the strain gauge is used for hydraulic pressure. Quartz Piezoelectric Transducer

The quartz piezoelectric transducer generates an electrical potential proportional to the pressure applied to it. The cavity pressure is calculated by employing the formula: F P = ----A The transducer provides an area to which the internal forces of the mold cavity are applied. Since the area is constant, the pressure is calculated by simply dividing the force applied, by the constant area. The piezoelectric potential is relatively small, it must be amplified before being sent on to the electronic control unit. Typically, the mold cavity pressure transducer produces a potential of approximately 5 mV/bar. Strain Gauge Transducer

The strain gauge is used in a Wheatstone bridge configuration, which employs a system of balanced resistances resulting in a null voltage situation under relaxed conditions. As pressure is applied to the strain gauge, the value of the resistance increases causing an imbalance in the null situation. This results in a voltage output proportional to the pressure applied, as the pressure increases, the output voltage increases. Strain gauges are made using a conductor which is bonded to a mounting surface in a zig-zag pattern. As the pressure applied to the surface of the strain gauge increases, the length of the conductor increases while the cross-sectional area decreases, causing an increase in resistance. Located on the hydraulic pressure transducer are potentiometers for calibrating minimum and maximum pressure limits, these should be adjusted so that the electronic control unit pressure readings agree with the pressure gauge readings.

R4 + VOLTAGE SUPPLY _

+

R3 VOLTAGE _ OUT

R1

R2

STRAIN GAUGE

As the resistance of R1 (strain gauge) increases voltage out increases

300

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE:

CONDUCTOR

APPLIED

APPLIED

PRESSURE

PRESSURE

CONNECTING

MOUNTING

POINTS

SURFACE

As the applied pressure increases the resistance increases

Figure 7.16 Strain Gauge Transducer.

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7. ELECTRICAL SYSTEM.

301

MAINTENANCE: 13.4 SCREW RPM TRANSDUCER The transducer that measures the screw RPM is a magnetic proximity switch, and is located beside the coupling which joins together the screw and the screw motor drive shaft. When a ferrous material (i.e. a bolt) comes into close proximity with the switch, a current is induced in the coil of the proximity switch. As the ferrous material moves away, the induced current subsides. These current spikes are counted, in an electronic unit, to determine the number of revolutions per minute of the shaft . The proximity switch, monitoring the screw RPM, is actuated by a bolt mounted onto the coupling that joins the screw and the screw motor drive shaft. As the screw turns, the bolt head comes into close "proximity" to the switch once every revolution. Engel uses this type of transducer to monitor the revolutions of the mold height adjustment motor during "automatic mold height adjustment".

13.5 THERMOCOUPLE TRANSDUCERS Injection molding machines use thermocouples to monitor temperatures. A thermocouple consists of two leads of dissimilar metal joined at one end and surrounded by a protective casing. The unit is inserted into the area to be monitored and the other end of the leads are connected to an electronic control unit. The thermocouple operates on the principle that when two dissimilar metals are heated they will produce a voltage approximately proportional to the temperature rise at that junction. The most commonly used metals for thermocouples are iron (Fe) and constantan (Ko).

NOTE! Ensure that the two thermocouple leads are connected to the correct terminals. If the leads are crossed, the thermocouple will not operate correctly. To ensure correct connection, use a magnet to detect the iron (Fe) lead which is magnetic and the constantan (Ko) lead which is not magnetic.

In order to assist you in troubleshooting, the table below indicates the millivolt readings you should be getting using an iron-constantan (FeKo) thermocouple. Table 7.5 Thermocouple Output / Temperature rise in oC oC mV mV/ oC 0 0 0 10 .52 .052 20 1.05 .053 30 1.58 .053 40 2.11 .053 Normal 50 2.65 .053 operating 60 3.19 .053 range 70 3.73 .053 80 4.27 .053 90 4.82 .054 100 5.37 .054

302

Table 7.6 Thermocouple Output / Temperature rise in oF oF mV mV/ oF 32 0 0 50 .52 .010 68 1.05 .015 86 1.58 .018 104 2.11 .020 122 2.65 .022 140 3.19 .023 158 3.73 .024 176 4.27 .024 194 4.82 .025 212 5.37 .025

7. ELECTRICAL SYSTEM.

Normal operating range

16/12/05

MAINTENANCE: Transducer 1 2 3 4 5 7 9

Application Mold Stroke Injection Stroke Nozzle Stroke Ejector Stroke Hydraulic Pressure Clamp Force Moog Valve

Position Operator side moving platen Injection unit Injection carriage Ejector plate Injection cylinder Non operator side upper tie bar Moog valve on injection unit

Diagram Analog Analog Analog Analog Analog Analog Analog (supply voltage & analog output-A06)

Switch *B1 (A01) *BG2 (A01) Z1 Z2 F1 F2 IE DZ OEN

Voltage 24 V dc 24 V dc 24 V dc 24 V dc 24 V dc 24 V dc 24 V dc 24 V dc 24 V dc

Toggle guide support Toggle guide support Moving platen Lubrication oil tank Suction filter - hydraulic oil tank Moog valve filter Mold height motor Injection unit - rear of barrel Level indicator - hydraulic oil tank

Digin 1 Digin 1 Digin 1 Digin 1 Digin 1 Digin 1 Analog Analog Digin 1

B1

BG2

IE 2

3

4 Z1 Z2

1

7

F2

OEN F1

5

DZ B1

9

BG2

Figure 7.17 Transducers and Switches 80/ 100.

16/12/05

7. ELECTRICAL SYSTEM.

303

MAINTENANCE: Transducer 1 2 3 4 5 9 Switch E1, E2 E3, E4 E9 E9/1 E9/2, E9/3 E10 E52 F1 F2 F2/2 DZ OEN

Application Mold stroke Injection stroke Nozzle stroke Ejector stroke Hydraulic pressure Moog valve Voltage 24 Vdc 120 Vac 24 Vdc 24 Vdc 24 Vdc 120 Vac 24 Vdc 24 Vdc 24 Vdc 24 Vdc 24 Vdc 24 Vdc

1

E2

E4

4

Position Operator side - clamp cylinder Non operator side - injection unit Operator side - injection unit Non operator side - ejector plate Injection manifold Moog valve Injection unit

Diagram Analog Analog Analog Analog Analog Analog

Under operator gate Under non operator gate Inside injection unit moving guard Inside injection unit side door Inside injection unit rear door Operator side moving platen drop bar Injection unit swinging guard Suction filter Pressure filter Moog valve filter Injection unit - end of barrel Level indicator - hydraulic oil tank

Digin 1 Drive Digin 1 Digin 1 Digin 1 Drive Digin 1 Digin 1 Digin 1 Digin 1 Analog Digin 1

E10

E3

E1

E9/3

E9

2

3

F1

E52

F2

F2/2

E9/2 E9/1

5

9 OEN

DZ A7530460

E2

E1

E9

E52

Figure 7.18 Transducers and Switches 30/55 .

304

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: Transducer

Application

Position

Diagram

1

Toggle stroke

Operator side - clamp cylinder

Analog

2

Injection stroke

Non operator side - injection unit

Analog

3

Nozzle stroke

Operator side - injection unit

Analog

4

Ejector stroke

Non operator side - ejector plate

Analog

5

Hydraulic pressure Injection manifold

Analog

7

Clamp force

Non operator side upper tie bar

Analog

9

Moog valve

Moog valve - injection unit

Analog

Switch

Voltage

E1, E2

24 Vdc

under operator gate

Digin 1

E3, E4

120 Vac

under non operator gate

Drive

E8

24 Vdc

Inside hydraulic interlock valve

Digin 1

E9

24 Vdc

Inside injection unit moving guard

Digin 1

E22

120 Vac

Operator side

Drive

E23

120 Vac

Operator side

Drive

E52

24 Vdc

Inside injection unit swinging guard

Digin 1

F1

24 Vdc

Suction filter

Digin 1

F2/1

24 Vdc

Moog valve filter

Digin 1

F2/2

24 Vdc

Pressure filter

Digin 1

Z1

24 Vdc

Moving platen

Digin 1

Z2

24 Vdc

Top - Lubrication oil tank

Digin 1

DZ

24 Vdc

Injection unit - end of barrel

Analog

OEN

24 Vdc

Level indicator - Hydraulic oil tank

Digin 1

IE

24 Vdc

Mold height motor

Analog

Transducers and Switches ES 85 and 100N-D

16/12/05

7. ELECTRICAL SYSTEM.

305

MAINTENANCE: 1

IE

E22

E23

Z2

E52*

E2

E4

E8

4

Z1

E1

E3

E2

3

E1

E9

7

2

E9

9

DZ

5

F2/1

E52

F1

OEN

DZ

Figure 7.19 Transducers and Switches ES 85 and 100N-D

306

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: TransApplication ducer 1 Toggle stroke

Voltage

Position

Diagram

10 Vdc

Operator side - clamp cylinder

Analog

2

Injection stroke

10 Vdc

Non operator side - injection unit

Analog

3

Nozzle stroke

10 Vdc

Operator side - injection unit

Analog

4

Ejector stroke

10 Vdc

Non operator side - ejector plate

Analog

5

Hydraulic pressure

24 Vdc

Injection manifold

Analog

7

Clamp force

5 Vdc

Non operator side upper tie bar

Analog

9

Moog valve

10 Vac

Moog valve - injection unit

Analog

B1

A01 only

24 Vdc

Toggle guide support

Digin 1

BG2

A01 only

24 Vdc

Toggle guide support

Digin 1

F1

Suction Filter OK

24 Vdc

Suction filter

Digin 1

F2

High Pressure Filter OK

24 Vdc

Moog valve filter

Digin 1

Z1

Lubrication Pressure OK

24 Vdc

Moving platen

Digin 1

Z2

Lubrication Oil Level OK

24 Vdc

Top - Lubrication oil tank

Digin 1

DZ

Injection Screw RPM

24 Vdc

Injection unit - end of barrel

Analog

OEN Oil Level OK

24 Vdc

Level indicator - Hydraulic oil tank

Digin 1

IE

Mold Height Motor RPM

24 Vdc

Mold height motor

Analog

E1

Safety Gate closed

24 Vdc

Operator side gate

Digin 1

E2

Safety Gate open

24 Vdc

Operator side gate

Digin 1

E3

Safety Gate closed

120 Vac

Non operator side gate

Drive

E4

Safety Gate open

120 Vac

Non operator side gate

Drive

E5

Safety Door is Open

120 Vac

Mold Height Area Safety Door

Drive

E6

safety Door is Open

120 Vac

Mold Height Area Safety Door

Drive

E8

Hydraulic Interlock

E8.1

Safety gate not closed

E9

Switch

Clamp Manifold

Digin 1

24 Vdc

Operator side safety gate

Digin 1

Purge Guard closed

24 Vdc

Purge guard

Digin 1

E22

Mold Height increase end

120 Vac

Non operator side tie bar support

Drive

E23

Mold Height decrease end 120 Vac

Non operator side tie bar support

Drive

AS1

Plexi glass shield open

24 Vdc

Operator side plexi glass shield

Digin 1

AS2

Plexi glass shield open

24 Vdc

Non operator side plexi glass shield

Digin 1

E52

Injection unit aligned

24 Vdc

Injection unit base

Digin 1

Transducers and Switches ES150 to ES250

16/12/05

7. ELECTRICAL SYSTEM.

307

MAINTENANCE: AS1

B1

1

E5, E6

IE

BG2

E2

E1

E8 AS2

Z2

4

E23 E4

E10

Z1

3

E22 E3

7

OEN

9

F1

E5 F2

2

5 3

E6 AS1 B1 BG2

1

E8.1

E2

A7530448

E1

E52

DZ

Figure 7.20 Transducers and Switches ES150 to ES250.

308

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: T'ducer

Application

Voltage

Position

Diagram

BU-1

Mold Stroke

10 Vdc

Operator Side Moving Platen

Analog

BU-2

Injection Stroke

10 Vdc

Op. Side Injection Carriage

Analog

BU-3

Nozzle Stroke

10 Vdc

Injection Unit

Analog

BU-4

Ejector Stroke

10 Vdc

Ejector Plate

Analog

BF

Injection Unit Pressure

24 Vdc

Non Op. Side Injection Carriage

Analog

BU-7

Clamp Force

5 Vdc

Non Op. Side Upper Tie Bar

Analog

DZ

Injection Screw RPM

Injection Unit rear End of Barrel

Analog

IE

Mold Height Motor RPM

Back of Mold Height Motor

Analog

Switch

b82

Main Motor Filter Open

24 Vdc

Non-Operator Side Main Motor

Digin 3

E1

Safety Gate Closed

24 Vdc

Operator Side Safety Gate

Digin 1

E2

Safety Gate Open

24 Vdc

Operator Side Safety Gate

Digin 1

E3

Safety Gate is Closed

120 Vac Non-Operator Side Safety Gate

Drive

E4

Safety Gate Is Open

120 Vac Non-Operator Side Safety Gate

Drive

E5

Safety Door is Open

120 Vac Mold Height Area Safety Door

Drive

E6

safety Door is Open

120 Vac Mold Height Area Safety Door

Drive

E8

Hydraulic Interlock Valve

24 Vdc

Clamp Manifold

Digin 1

E8.1

Hyd. Closing Safety O.K.

24 Vdc

Operator Side

Digin 1

E9

Sliding In. Guard Closed

24 Vdc

Sliding Inj. Guard over Nozzle End

Digin 1

E22

Mold Height Increase End

120 Vac Operator Side near Mold Height Motor

Drive

E23

Mold Height Decrease End

120 Vac Operator Side near Mold Height Motor

Drive

E52

Injection Unit Aligned

24 Vdc

Operator Side Injection Unit

Digin 1

F1

Suction Filter O.K.

24 Vdc

Hydraulic Tank

Digin 1

F2

High Pressure Filter O.K.

24 Vdc

Non Operator Side Injection Manifold

Digin-1

OEN

Oil Level O.K.

24 Vdc

Hydraulic Tank

Digin-1

Z1

Lubrication Pressure O.K.

24 Vdc

Middle of Moving Platen

Digin-1

Z2

Lubrication Oil Level O.K.

24 Vdc

Non Operator Side Oil Tank

Digin-1

Transducers and Switches ES300 to ES500

16/12/05

7. ELECTRICAL SYSTEM.

309

MAINTENANCE: BU-1

Z1

E5, E6 BU-3

IE E2

E8.1

E1

BU-7

BU-4 E8 Z2

BF, BU-2, F2

E22, E23 E4

E3

E9

F1 b82

E5 OEN

E6

E52

DZ

Figure 7.21 Transducers and Switches ES300 to ES500

310

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: Transducer

Application

Position

Card

BU - 1

Toggle Stroke

Operator side Lower Tiebar

Analog

BU - 2

Injection Stroke

Non Operator side Injection Unit

Analog

BU - 3

Nozzle Stroke

Operator side Injection Unit

Analog

BU - 4

Ejector Stroke

Ejector Plate

Analog

BU - 7

Clamp Force

Non Operator side upper Tiebar

Analog

BU - 8

Mold Height Stroke

Operator side Tiebar support

Analog

DZ

Injection Screw R.P.M.

Non Operator side of Injection unit

Analog

IE

Mold Height Motor R.P.M.

Back of Mold Height Motor

Analog

Switch

bDb

Mech. Closing Interlock released Top Of Moving Platen

Digin 2

E1

Safety Gate Closed

Operator side Safety Gate

Digin 1

E2

Safety Gate Not Closed

Operator side Safety Gate

Digin 1

E3

Rear Safety Gate L.S.

Non Operator side Safety Gate

120 Vac

E4

Rear Safety Gate L.S.

Non Operator side Safety Gate

120 Vac

E8

Hydraulic Clamp Interlock

Non Operator side Cylinder Platen

Digin 1

E8.1

Front Safety Gate Not Closed

Operator side Safety Gate

Digin 1

E9

Purge Guard Closed

Non Operator side Stationary Platen Digin 1

E10

Front Safety Gate

Operator side Safety Gate

120 Vac

E22

Max. Mold Height

Operator side Cylinder Platen

120 Vac

E23

Min. Mold Height

Operator side Cylinder Platen

120 Vac

E52

Injection Unit aligned

Non Operator side Injection Unit

Digin 1

F1.1

Suction Filter O.K.

Non Operator side near Motor 1

Digin 1

F1.2

Suction Filter O.K.

Non Operator side near Motor 2

Digin 1

F2

Servo Valve Filter O.K.

Non Operator side Injection unit

Digin 1

OEN

Oil Level O.K.

Hydraulic Tank

Digin 1

Z1

Lub. Oil Pressure O.K.

Top of Moving Platen

Digin 1

Z2

Lub. Oil Level O.K.

Lubrication Oil Tank

Digin 1

Z4

Lub. Grease Pressure O.K.

Rear of Cylinder Platen

Digin 2

Z5

Lube. Pressure 2 Max > ES800

Mold Height Motor area

Digin 1

Transducers and Switches ES600 to ES3500

16/12/05

7. ELECTRICAL SYSTEM.

311

MAINTENANCE: BU-1

BU-4

1E

Z1

OPERATOR SIDE

Z2 E23

E22

BU-7 Y4

Y3

F2

bZ4

F1.1

BU-2

F1.2 K2 Y2

K1 Y1

NON OPERATOR SIDE

E3, E4

E8

E9

E52

DZ

OEN

bDb Z5

E2

E8.1

E10

E1

BU-3

Figure 7.22 Transducers and Switches ES600 - ES3500

312

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: T'ducer

Application

Position

Card

BU-1

Mold Stroke

Underneath Clamp Cylinder

Analog

BU-2

Injection Stroke

Non operator side Injection unit

Analog

BU-3

Nozzle Stroke

Operator side Injection unit

Analog

BU-4

Ejector Stroke

Underneath Clamp Cylinder

Analog

BF

Hyd. Pressure

Injection Manifold

Analog

DZ

Injection Screw R.P.M.

Injection Unit rear end of barrel

Analog

E1

Safety Gate Closed

Operator side safety gate

Digin 1

E2

Safety Gate Open

Operator side safety gate

Digin 1

E3

Safety Gate Closed

Non operator side safety gate

120Vac

E4

Safety Gate Open

Non operator side safety gate

120Vac

E8

Hydraulic Interlock Engaged

Non operator side Clamp Manifold

Digin 1

E9

Injection Cover Open

Operator side injection cover- top rail Digin 1

E9.2

Injection Cover Open

Non operator side inj. cover - top rail

E21

Mechanical Closing Interlock Released Operator side

Digin 1

F1

Suction Filter O.K.

Hydraulic Tank

Digin 1

F2

High Pressure Filter O.K.

Non operator side Pump Manifold

Digin 1

G6

Limit of moving platen travel reached

Under clamp cylinder

Digin 1

OEN

Oil Level O.K.

Hydraulic Tank - rear

Digin 1

Switch

Digin 1

Three door machines ES40TL & ES60TL

S5

Electrical Cabinet Door Open

R.H.S. Door opening

S6

Electrical Cabinet Door Open

Middle Door opening

S6.1

Electrical Cabinet Door Open

L.H.S. Door opening

Four door machines ES100TL

S5

Electrical Cabinet Door Open

R.H.S. Door opening

S5.1

Electrical Cabinet Door Open

R.H.S. Middle Door opening

S6

Electrical Cabinet Door Open

L.H.S. Middle Door opening

S6.1

Electrical Cabinet Door Open

L.H.S. Door opening

Transducers and Limit Switches Tiebarless Injection Molding Machines ES40TL, ES60TL And ES100TL

16/12/05

7. ELECTRICAL SYSTEM.

313

MAINTENANCE: INJECTION STROKE TRANSDUCER

E21

E9

G6

E1 E2

S6.1

EMERGENCY STOP

EJECTOR STROKE AND CLAMP STROKE

S6

S5

MAIN ISOLATOR

TRANSDUCER

HYDRAULIC PRESSURE TRANSDUCER

E8 E4

E3

E9.2

F2 F1

OEN

NOZZLE STROKE TRANSDUCER

7.23 Transducers and Limit Switches Tiebarless Injection Molding Machines ES40TL, ES60TL And ES100TL

314

7. ELECTRICAL SYSTEM.

16/12/05

MAINTENANCE: Trans ducer 1 2 3 4 5 9 DZ FH Switch 24Vdc b74† b75† b77 b82 bDWV* bSGZB* bSPI DTH DTVE DTVV E1* E2* E52 E8.1* E9 F1 F2 F2.2 MFSI OEN

Application

Position

Card

Mold Stroke Injection Stroke Nozzle Stroke Ejector Stroke Hydraulic Pressure Moog Valve Screw Rotation Table Position

Clamp Yoke Non Operator side - Injection Unit Operator side - Injection Unit Under Rotary Table Injection manifold Injection Manifold Injection Unit Underneath Rotary Table

E8 Analog E8 Analog E8 Analog E8 Analog E8 Analog E16 Analog E8 Analog E16 Analog

Purge slide is in Purge slide is in Mechanical closing safety is out Prefill oil tank level OK Power safety gate lower strip Safety gate slow down Mold close interlock Table raised Table unlocked Table locked Safety gate closed Safety gate not closed Injection unit aligned Front gate not closed Purge guard closed Suction filter OK Pressure filter OK Pressure filter OK Mold flash safety interlock Oil level OK

Purge Plate - Clamp Yoke Purge Plate - Clamp Yoke Top of Clamp Yoke Prefill Oil Tank Front of Rotary Table on Safety Gate Sill Inside Safety Gate on Operator side Inner face of Operator side Clamp Yoke Underneath Rotary Table Underneath Rotary Table Underneath Rotary Table Non Operator side Safety Gate slide Non Operator side Safety Gate slide Carriage Cylinder Rod Clevis Operator side Clamp Yoke Purge Guard Suction Filter - rear - on oil tank Pressure Filter- rear - on oil tank Rear of Barrel (Mold Flash Safety Interlock) Non operator side - rear - on oil tank

Digin 3 Digin 3 Digin 3 Digin 3 Digin 2 Digin 2 Digin 1 Digin 3 Digin 3 Digin 3 Digin 1 Digin 1 Digin 1 Digin 1 Digin 1 Digin 1 Digin 1 Digin 1 Digin 3 Digin 1

NOTE!

* = ONLY USED WHEN THE SAFETY GATE IS FITTED † = ONLY USED WHEN THE LIGHT CURTAIN IS FITTED Some options may require the addition, deletion or relocation of certain items. Transducers and Switches ES55, 85, 125, 150 and 200 Ton Rotary Bridge

16/12/05

7. ELECTRICAL SYSTEM.

315

MAINTENANCE:

E1, E2, bSGZB

b52

b8.2

*

2

b75 F1 F2 OEN

bDVW *

F2.2 1 4

b77

b74

E2 *

5 AND 9

3

bSP1

† ONLY USED WITH LIGHT CU

E8.1 * * ONLY USED WITH A PNEUMATIC SAFETY GATE MFSI

b74 † b75 †

DZ

E9

bSGZB

E1 * DTH FH DTVR DTVV

Figure 7.24 Transducers and Switches ES55, 85, 125, 150 and 200 Ton Rotary Bridge

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: 14.

STANDARD SOLENOID LOCATION

The following tables and figures detail, the application, hydraulic manifold location and the electronic card associated with a particular solenoid. The figures generally cover the range of Engel machines and show the usual location of solenoids and their associated hydraulic manifolds. Individual machines may vary as to the location of solenoids and manifolds depending upon the options supplied with that machine. Solenoid Application

Location

Card

S1

Clamp Close

Clamp Manifold

Digout 1

S1.2

Clamping High Pressure

Clamp Manifold

Digout 1

S2

Clamp Open

Clamp Manifold

Digout 1

S2.1

Prefill Valve Opening

Clamp Manifold

Digout 1

S2.2

Prefill Chamber venting

Clamp Manifold

Digout 1

S3

Plasticizing / Screw Feed

Injection Manifold

Digout 1

S3A

Back Pressure

P/Q Manifold

Digout 1

S4

Injection

Injection Manifold

Digout 1

S4D

Regenerative Injection

Injection Manifold

Digout 2

S6

Nozzle Back

Injection Manifold

Digout 1

S6A

Release Nozzle Contact Pressure

Injection Manifold

Digout 1

S12A

Regenerative Clamp Close

P/Q Manifold

Digout 2

S14

Core Pull 1 Out

Ejector/Corepull Manifold

Digout 3

S15

Core Pull 1 In

Ejector/Corepull Manifold

Digout 3

S25

Ejector Forward

Ejector/Corepull Manifold

Digout 1

S26

Ejector Back

Ejector/Corepull Manifold

Digout 1

NON OPERATOR SIDE

EJECTOR / COREPULL MANIFOLD

P/Q MANIFOLD INJECTION MANIFOLD

CLAMP MANIFOLD

A7530460

Figure 7.25 Solenoids 30/55 .

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MAINTENANCE: Solenoid Application

Location

Card

S1

Clamp Close

Clamp Manifold

Digout 1

S2

Clamp Open

Clamp Manifold

S3

Screw Feed/Plasticizing

P/Q Manifold

Digout 1

S3A

Back Pressure

P/Q Manifold

Digout 1

S4

Injection

Injection Manifold

S4D

Regenerative Injection

Injection Manifold

Digout 2

S5

Injection Unit Forward

P/Q Manifold

Digout 1

S6

Injection Unit Back

P/Q Manifold

Digout 1

S10

Pump 1 Enable

P/Q Manifold

Digout 1

S14

Core 1 Out/Unscrewing

Ejector/Corepull Manifold

Digout 3

S15

Core 1 In/Rewind

Ejector/Corepull Manifold

Digout 3

S16

Core 2 Out/Unscrewing

Ejector/Corepull Manifold

Digout 3

S17

Core 2 In/Rewind

Ejector/Corepull Manifold

Digout 3

S24

Decomp. / Screw Retract

Injection Manifold

Digout 1

S25

Ejector Forward

Ejector/Corepull Manifold

Digout 1

S26

Ejector Back

Ejector/Corepull Manifold

Digout 1

SFT

Feed Throat Cooling

Non Op. Side/Heat Exchanger

S43

Cooling Water

Non Op. Side/Heat Exchanger Digout 2 NON OPERATOR SIDE

CLAMP MANIFOLD

EJECTOR / COREPULL MANIFOLD

FEEDTHROAT MANIFOLD INJECTION MANIFOLD

P/Q MANIFOLD

Figure 7.26 Solenoids ES 85 and 100N-D

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: Solenoid

S1 S2 S3 S3A S4 S4D S5 S6 S6A S10 S11 S12A S14 S15 S16 S17 S24 S25 S26 S40 S41 S65 S66 SFT S43 Y3 Y4

Application

Location

Clamp Close Clamp Open Screw Feed/Plasticizing Back Pressure Injection Regenerative Injection Injection Unit Forward Injection Unit Back Release Nozzle Contact Pressure Pump 1 Enable Mold Protection Pressure Regenerative Clamp Core 1 Out/Unscrewing Core 1 In/Rewind Core 2 Out/Unscrewing Core 2 In/Rewind Decomp. / Screw Retract Ejector Forward Ejector Back Moving Platen Mold Release Stationary Platen Mold Release Purge Hopper to Feed Material Hopper to Feed Feed Throat Cooling Cooling Water Proportional Screw Rotation Moog Valve

Clamp Manifold Clamp Manifold P/Q Manifold or Injection Manifold P/Q Manifold or Injection Manifold P/Q Manifold or Injection Manifold Injection Manifold P/Q Manifold P/Q Manifold Injection Manifold P/Q Manifold P/Q Manifold Clamp Manifold Ejector/Core Manifold Ejector/Core Manifold Ejector/Core Manifold Ejector/Core Manifold Injection Manifold Ejector/Core Manifold Ejector/Core Manifold Ejector/Core Manifold QMC Manifold Injection Manifold Injection Manifold Non Op. Side/Heat Exchanger Non Op. Side/Heat Exchanger Injection Manifold Clamp Manifold

CLAMP MANIFOLD

EJECTOR MANIFOLD

S41

P/Q MANIFOLD

Card

Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 Digout 2 Digout 1 Digout 1 Digout 1 Digout 1 Digout 2 Digout 1 Digout 3 Digout 3 Digout 3 Digout 3 Digout 1 Digout 1 Digout 1 Digout 3 Digout 3 Digout 5 Digout 5 Digout 2

INJECTION MANIFOLD

SFT, S43

Figure 7.27 Solenoids ES150 to ES500

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MAINTENANCE: Solenoid

K1 K2 S3 S4 S4D S5 S6 S6A S9 S10 S10A S12A S14 S15 S16 S17 S18 S19 S24 S25 S26 S40 S41 S43 S46 S47 S52 S55 S56 S70 S71 MGM MGS SAA SAE SFT SM1 SM2 Y1 Y2 Y3 Y4

Application

Location

Card

Clamp Pressure Carriage & Sec. Mov.Press.Cont. Screw Feed / Plasticizing Injection Regenerative Injection Injection Unit Forward Injection Unit Back Nozzle Pressure Release Pump 1 System 1 Pump 1 System 2 Pump 2 System 2 Regenerative Clamp Core 1 Out / Unscrewing Core 1 In / Rewind Core 2 Out / Unscrewing Core 2 In / Rewind Core 3 Out / Unscrewing Core 3 In / Rewind Decomp. / Screw Retraction Ejector Forward Ejector Back Release Moving Mold Half Release Stationary Mold Half Oil Cooling Pump System Separation Pump System Flow Control Grease System Area 2 Release Mechanical Drop Bar Leakage Comp. Moog Valve Secure Moving Mold Half Secure Stationary Mold Half Mold Gate Moving Mold Gate Stationary Injection Unit Swivelling Out Injection Unit Swivelling In Feed Throat Cooling Mold Closing Pressure Comp. Mold Opening Pressure Comp. Mold Opening/Closing Carriage & Sec. Move. Sp. Cont. Proportional Screw Rotation Moog Valve

Clamp Manifold Clamp Manifold Injection Manifold Injection Manifold Injection Manifold Carriage Manifold Carriage Manifold Carriage Manifold Pump Manifold Pump Manifold Pump Manifold Clamp Manifold Ejector / Core Manifold Ejector / Core Manifold Ejector / Core Manifold Ejector / Core Manifold Ejector / Core Manifold Ejector / Core Manifold Injection Manifold Ejector / Core Manifold Ejector / Core Manifold Mold Clamp/Master Gate Shut off Mold Clamp/Master Gate Shut off Pump Manifold Pump Manifold Pump Manifold Moving Platen Operator side Tiebar support Injection Manifold Mold Clamp/Master Gate Shut off Mold Clamp/Master Gate Shut off Mold Clamp/Master Gate Shut off Mold Clamp/Master Gate Shut off Injection Manifold Injection Manifold

Press. Valve Press. Valve Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 Digout 3 Digout 4 Digout 4 Digout 4 Digout 1 Digout 3 Digout 3 Digout 3 Digout 3 Digout 4 Digout 4 Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 E8-Temp 1 Digout 3 Digout 3 Digout 1 Digout 4 Digout 4 Digout 5 Digout 5 Digout 2 Digout 2 Digout 1 Digout 1 E8-Temp2 Digout 4 Digout 1 Sp/Dir Valve. Speed Valve Speed Valve Speed Valve

Clamp Manifold Clamp Manifold Clamp Manifold Carriage Manifold Injection Manifold Injection Manifold

Solenoids ES600 to ES3500

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7. ELECTRICAL SYSTEM.

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MAINTENANCE:

BOX D

BOX B1

INJECTION MANIFOLD

BOX B

BOX A

S52

S55 CARRIAGE PUMP MANIFOLD MANIFOLD BOX TB5 S43

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MOLD CLAMP/ MASTER GATE SHUT OFF MANIFOLD

7. ELECTRICAL SYSTEM.

EJECTOR/CORE MANIFOLD

CLAMP MANIFOLD

BOX TB3

321

MAINTENANCE: Solenoid S1 S1.2 S2 S2.1 S2.2 S3 S3A S4 S4D S5 S6 S6A S10 S12A S14 S15 S16 S17 S24 S25 S26 S40 S41

Application Clamp close Clamping High Pressure Clamp open Prefill Valve Opening Prefill Chamber Venting Plasticizing / Screw feed Back Pressure Injection Regenerative Injection Nozzle forward Nozzle back Release Nozzle contact pressure Pump Loading Regenerative Clamp Close Core pull 1 - out Core pull 1 - in Core pull 2 - out Core pull 2 - in Screw retract Ejector forward Ejector back Moving Platen Quick Mold Release Stat. Platen Quick Mold Release

Location Clamp Manifold Prefill Manifold Clamp Manifold Prefill Manifold Prefill Manifold Injection Manifold P/Q Manifold Injection Manifold Injection Manifold Injection Manifold Injection Manifold Injection Manifold P/Q Manifold P/Q Manifold Core pull Manifold Core pull Manifold Core pull Manifold Core pull Manifold Injection Manifold Ejector Manifold Ejector Manifold

Card Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 Digout 1 Digout 2 Digout 1 Digout 1 Digout 1 Digout 1 Digout 2 Digout 3 Digout 3 Digout 3 Digout 3 Digout 1 Digout 1 Digout 1 Digout 3 Digout 3

COREPULL MANIFOLD PREFILL MANIFOLD

CLAMP MANIFOLD INJECTION MANIFOLD

P/Q MANIFOLD

EJECTOR MANIFOLD

7.29 Solenoids - Tiebarless Injection Molding Machines ES40TL, ES60TL and ES100TL

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MAINTENANCE: Solenoid

Application

Location

Card

S1

Mold Close

Clamp Manifold

Digout 1

S2

Mold Open

Clamp Manifold

Digout 1

S3

Screw Rotation

Injection Manifold

Digout 1

S4

Injection

Injection Manifold

Digout 1

S5

Injection Unit Forward

Injection Manifold

Digout 1

S6

Injection Unit Back

Injection Manifold

Digout 1

S10

Pump 1 Enable

Pump Manifold

Digout 1

S11A

Mold Protection Enable

Clamp Manifold

Digout 3

S11B

Mold Protection Relief

Clamp Manifold

Digout 3

S3A

Back Pressure

Pump Manifold

Digout 1

S25

Table Ejector Forward

Table Manifold

Digout 1

S26

Table Ejector Back

Table Manifold

Digout 1

S2.2

Release Clamp Pressure

Clamp Manifold

Digout 1

S1.3

Allow Clamping High Pressure

Clamp Manifold

Digout 1

S9

Pump 2 Enable

Digout 1

S6A

Release Nozzle Contact Pressure Injection Manifold

Digout 1

S4D

Regeneration. Injection

Digout 2

S60

Mechanical Safety Bar Out

Injection Manifold

Digout 4

SDTCCW Rotate Table Counter Clockwise

Table Manifold

Digout 4

SDTCW

Rotate Table Clockwise

Table Manifold

Digout 4

SDTH

Raise Table

Table Manifold

Digout 3

SDTL

Lower Table

Table Manifold

Digout 4

SDTVV

Secure Table

Table Manifold

Digout 3

SDTVE

Release Table

Table Manifold

Digout 3

S84

Table Core 1 In

Ejector/Core Manifold

Digout 6

S85

Table Core 1 Out

Ejector/Core Manifold

Digout 6

S86

Table Core 2 In

Ejector/Core Manifold

Digout 6

S87

Table Core 2 Out

Ejector/Core Manifold

Digout 6

Solenoids ES55, 85, 125, 150 and 200 Ton Rotary Bridge

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MAINTENANCE: TABLE MANIFOLD

INJECTION MANIFOLD

PUMP MANIFOLD

EJECTOR/CORE MANIFOLD

CLAMP MANIFOLD

NOTE! Some options may require the addition, deletion or relocation of certain items. Figure 7.30 Solenoids ES55, 85, 125, 150 and 200 Ton Rotary Bridge

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MAINTENANCE: 15.

SETTING MINIMUM AND MAXIMUM BALANCE ON PA88 CARD (Pressure and Flow)

NOTE! There are no adjustment potentiometers on the PA89 card. If you replace a PA88 card with the PA89 card, disregard this section.

This must only be attempted if the value has been changed, an analog card has been replaced, or if maximum speeds or pressures cannot be achieved. There are 4 adjustment potentiometers for balancing the minimum and maximum current levels for each of the K and Y valves. Two are for coarse adjustment and two are for fine adjustment.

Pressure

Flow

KO

-

Zero point (coarse)

KM

-

Maximum (coarse)

KEO

-

Input Zero point (fine)

KEM

-

Input Amplification (fine)

YO

-

Zero point (coarse)

YM

-

Maximum (coarse)

YEO

-

Input Zero point (fine)

YEM

-

Input Amplification (fine)

Figure 7.31 indicates the effect of turning the potentiometers clockwise (cw) or counterclockwise (ccw).

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MAINTENANCE:

Setting Minimum/Maximum Valve Function

100 %

CCW

KM KEM YM YEM

CW

CCW CW

0% K0 KE0 Y0 YE0

0

2

9

10 Volts

The potentiometers K0, KE0, Y0, YE0, KM, KEM, YM and YEM are all found on the PA88 card. These potentiometers are used to adjust the minimum and maximum valve function at 2 and 9 volts, respectively. The machine calibration program looks after all points in between.

Figure 7.31

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MAINTENANCE: 16.

SETTING THE MINIMUM / MAXIMUM POINT FOR PRESSURE (K-VALVE) - A02 CONTROLS (30 Ton - 500 Ton).

NOTE! This procedure is for open loop machines only. On a closed loop machine, follow the proceedure below, but use the ejector function instead of the injection functions. Set the ejector reduction factors to 100%. Select pressure gauge position 1 not 3. Use ejector pressure P25 not injection pressure P6. Return all settings back to the original values.

In manual mode, advance the screw (inject) until it stops. Activate the time dependent cutoff function and set variable Z1 to 100 seconds. Set the injection speed profile to 3 inches per second. Go to the main pressure calibration page and press "1" to initialize the calibration curve (see figure 7.32). 30 - 250 Ton K-Valve (1 pump) 300 - 500 Ton K-Valve (2 pumps) 5. On the injection page, set P6 pressure to 20% of maximum and activate the manual injection switch. At this point, 2 volts will appear on terminal K1 on the PA88 card. 6. Adjust potentiometer KEO until the pressure just starts to rise. This is the minimum pressure indication. Pressure can be monitored on gauge position 3 or on any screen page that displays PHx actual hydraulic pressure. 7. Now set P6 to 90% of maximum pressure and activate the manual injection switch. At this point, 9 volts will appear on terminal K1 on the PA88 card. 8. Adjust potentiometer KEM until the pressure is at maximum. 9. After setting the maximum pressure, re-check the minimum pressure setting to make sure that it has not changed. If there has been a change, repeat the above procedure until the correct settings have been established. 10. The pressure functions must now be calibrated. Return to the pressure calibration page and calibrate all pressure functions in the prescribed manner as set out in the calibration instructions. 1. 2. 3. 4.

NOTE! Remember to change the injection speeds and cut-off variables back to their original settings.

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MAINTENANCE: CALIBRATION PRESSURE K VALVE (2 pumps)

SM1 TABLE TYPE 100%= 2320 psi

100% 80%

60%

40%

20%

0% +0

+1

+2

+3

+4

+5

+6

+7

+8

+9

+ 10V

0 ... MAIN MENU 1 ... INITIALIZATION 2 ... MEASUREMENT 3 ... ACCEPT DATA 4 ... CHANGE DATA

When the manual switch is activated, 2 volts will be output at 20% valve function and 9 volts will be output at 90% valve function.

Figure 7.32

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MAINTENANCE: 17

SETTING THE MINIMUM /MAXIMUM POINT FOR SPEED (Y-VALVE) - A02 CONTROLS (30 Ton - 500 Ton)

6.

On the Screw Refill page set C2 equal to 0.00 inches, C4 and C1 equal to a value 1 inch less than the maximum screw stroke and then manually activate the screw refill key (Feed).

7.

Now set C1 to the maximum screw refill stroke position and set C4 equal to 0.00 in.

8.

Go to the Screw RPM Calibration page and press "1" to initialize the calibration curve (see figure 7.33).

9.

On the Screw Refill page, set the screw refill speeds to 20% and activate the manual screw refill switch. At this point, 2 volts will appear on terminal Y1 on the PA88 card.

10. Adjust potentiometer YEO until the screw just barely starts to turn. This is the minimum flow indication. 11. Now set the screw refill speeds to 90% and activate the manual screw refill switch. At this point, 9 volts will appear on terminal Y1 on the PA88 card. 12. Adjust potentiometer YEM until the Screw RPM rate is at maximum. See section "General Machine Specification" for details on maximum RPM rates. 13. After setting the maximum RPM, recheck the minimum RPM setting to make sure that it has not changed. If there has been a change, repeat the above procedures until the correct settings have been established. 14. All speed functions must now be calibrated. Return to the speed calibration pages and calibrate all speed functions in the prescribed manner as set out in the calibration instructions.

NOTE! If the machine has two pumps, balancing of the card must be done for each pump circuit separately. The machine with two pumps will also have an extra PA88 card to control the second flow valve Y2. The balancing procedures are the same as outlined above, but when balancing one pump circuit, the other pump circuit must be disconnected from the system (see step 10). 15. For machines with 2 pumps, unhook the flow control solenoid Y2 when you are balancing the first PA88 card. Likewise, when you are balancing the second PA88 card, unhook the flow control solenoid Y1.

If the two pumps have a different GPM flow capacity, their maximum screw RPM potential will be different as well. For example, a 300 Ton machine has a top screw RPM rating of 217. However, the Y1 valve for the variable displacement pump has a maximum of 119 RPM potential, while the Y2 valve for the fixed displacement pump has a maximum of 98 RPM potential.

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329

MAINTENANCE:

NOTE! Remember to change the screw refill and decompression variables back to their original settings.

CALIBRATION SCREW RPM Y - VALVE

SM1 TABLE TYPE 100%= 238 rpm

100% 80%

60%

40%

20%

0% +0

+1

+2

+3

+4

+5

+6

+7

+8

+9

+ 10V

0 ... MAIN MENU 1 ... INITIALIZATION 2 ... MEASUREMENT 3 ... ACCEPT DATA 4 ... CHANGE DATA

When the manual switch is activated, 2 volts will be output at 20% valve function and 9 volts will be output at 90% valve function.

Figure 7.33.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: 18

REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - type LG83

NOTE! As a preventive maintenance suggestion, the maintenance technician should record the millivolt signal that appears across SK3 (plus) and SK4 (minus) with the mold open completely to the 'A' position and locked up at full tonnage.

•

Clamp Force Transducer. Open the mold completely to the 'A' position.

•

Screw the transducer pin all the way into the movable rod and tighten the fine adjustment lock nut.

•

With caution, screw the transducer housing in until you can just feel the transducer pin bottom out within the housing and then turn the housing out again approximately three complete turns.

•

Connect the cable and then turn on the control voltage.

•

Check for the transducer supply voltage across SK1 (0V) and SK2 (+5 volts).

•

With your voltmeter leads across SK3 (plus) and SK4 (minus), adjust the offset voltage by turning the transducer housing until you read the correct offset voltage (See note above). It will be approximately +70 mV. The transducer has a range of -5 volts to +5 volts. Make sure you are reading plus millivolt to start.

•

Tighten the lock nut (coarse adjustment).

•

If further adjustment is required, use the transducer pin position as a fine adjustment and then tighten the fine adjustment lock nut after completion.

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MAINTENANCE: 19

REPLACE OR ADJUST CLAMP FORCE TRANSDUCER -TYPE LG93

Installing the Transducer • Open the mold to position 'A'. • Introduce the rod of the transducer into the hole in the Tiebar. • When the rod reaches the bottom of the hole, there must be a gap between the transducer body and the end of the tiebar of between 0.060 and 0.120" (1.5 to 3mm). • Mount the transducer to the tiebar with two 5 mm cap screws. To set-up the Clamp Force Transducer. • Using a 3 mm Allen key remove the screw cover from the center of the transducer body. • Connect the cable to the transducer. • Turn on the Control Voltage. • Using a digital volt meter, check on the Analog card that the transducer supply across SK1 (0V) and SK2 (5V) is 5 Volts d.c. • Transfer the volt meter leads to SK3 (plus) and SK4 (minus) on the analog card. • Using a 1.5 mm Allen key, adjust the transducer through the hole of the screw cover removed in step 5. • Adjust the transducer for a reading of 70 mV d.c. on the volt meter. • Clamp up the mold using the maximum clamp force for the mold installed. • Check that the 'Clamp Force: Actual' is within the set tolerance to the 'Clamp Force: Set'.

Open the mold to position 'A' and check that the volt meter still reads 70 mV

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: 20.

REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - TYPE LG99 The tonnage applied to the mold is measured by the amount that the tiebar is stretched. The tiebar stretch is at a maximum of approximately 0.25mm. The amplifier in the transducer delivers between 200mV for mold open to approximately 9 Volts under full tonnage, depending upon the machine size. The transducer senses that stretch by viirtue of the compressed spring washers and measuring rod. Movement of the rod is converted to a voltage and fed to the analog card where it is processed by the controller and converted to a tonnage reading.

NOTE! The power supply for the transducer is ±12 Volts. The zero point of the transducer is monitored and if it does not reach 30mV (P36197) or exceeds 600mV (P36200) then the error message CF ZERO POINT is displayed. If parameter P35480 is set to 1 then the cycle stops. Cable break monitoring is performed at switch on and if a voltage of between 30mV and 500 mV is not detected, the system assumes an open circuit. Installing the Transducer • Open the mold to position 'A'. • Introduce the rod of the transducer into the hole in the Tiebar. • When the rod reaches the bottom of the hole, there must be a gap between the transducer body and the end of the tiebar of between 0.080 and 0.120" (2 to 3mm). • Mount the transducer to the tiebar with two 5 mm cap screws. To set-up the Clamp Force Transducer. • Using an Allen key remove the countersunk screw from the center of the transducer. • Connect the cable to the transducer and turn on the control voltage. • Use a 2.5 mm Allen key, to adjust the “offset voltage” potentiometer.

NOTE! Do not adjust the “offset” any further than necesary to be within range. •

16/12/05

Initially, a red and a green LED may be lit. The green LED will indicate which way to adjust the offset potentiometer to bring the transducer into the range. Turn the Allen key in the direction of the green LED. When both green LEDs are lit, the offset voltage is in the “range”.

7. ELECTRICAL SYSTEM.

333

MAINTENANCE: • •

• •

Using a digital multimeter, check on the PD 242/A card that the transducer supply across +12V and -12V is 24 Volts d.c. Transfer the multimeter to Ai0+ and Ai0- on the Analog card and adjust the offset potentiometer until the reading is approximately 300 milliVolts. When the adjustment has been made, replace the countersunk screw in the center of the transducer. Clamp up the mold using the maximum clamp force for the mold installed. Check that the 'Clamp Force: Actual' is within the set tolerance to the 'Clamp Force: Set'.

Details of the LG99 Clampforce transducer

334

7. ELECTRICAL SYSTEM.

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MAINTENANCE: 21.

USING THE MICROGRAPH AS AN OSCILLOSCOPE

In order to optimize system pressures and velocities, it is possible to display analog values on the video display unit. The analog outputs of the CC90 A01 and the EC88/CC90 A02 controllers have a resolution of 4096, representing -10 volts to +10 volts. However, we use 3001 - 6000 to represent -10 volts to 0 volts and 0 - 3000 to represent 0 volts to +10 volts. Some versions of software use different scales, but the concept remains the same. If your machine is in Bar pressure units, use a scale of 0 - 414. 3001 -------------------------> 6000, 0 -------------------------> 3000 ___________________________________________________ - 10 volts 0 volts + 10 volts Recognizing the above parameters, we can set up the Micrograph to display a line graph indicating these analog output voltages. Another possibility is to monitor the analog input representing the actual clamp speed during opening or closing. We use the cavity pressure variable on the Micrograph parameter page to set up the vertical scale of the graph. The horizontal scale is based on time. Examine the Micrograph page below and note the scale on the right hand side.

MICROGRAPH 100%

6000...0v

80%

60% 3001...-10v 3000...+10v

40%

20%

0% 0.00

2.00

4.00

6.00

8.00

0...0v 10.00

If the cavity pressure scale is set to 6000 psi, 0 - 10 volts will appear in the top half of the Micrograph display and 0 to +10 volts will appear on the bottom half of the Mirograph display

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MAINTENANCE: How to use this function 6. Go into the service Menu using password 22222222. 7.

Go to the P&V Control Parameters page and change the injection speed scanning time, "To", to the analog output channel number that you wish to examine.

Channel Number (on E16 Analog Card)

Valve

Function (30 - 600 ton ; new hydraulics)

A00

204.8

K

System Pressure

A01

230.4

Y1 & Y2

System Speed

A02

256.0

vacant

A03

281.6

vacant

A04

307.2

vacant

A05

332.8

YS1/2

Proportional Clamp

A06

358.4

Y4 (Moog)

Injection, Hold, Back Pr.

A07

384.0

vacant

332.9

Closing (mm/sec)

333.0

Opening (mm/sec)

8.

Go to the Micrograph parameter page and set curve 'a' and curve 'b' to 2, cavity pressure.

9.

Set the cavity pressure scale to 3000 for a display of 0 volts to +10 volts or to 6000 for a display of -10 volts to +10 volts. Remember that -10 volts to 0 volts will appear in an inverted form on the actual Micrograph curve.

10. Set the time base for 10 seconds. The time base should be set depending on how long the analog output is normally active. In any event, the time base sets the horizontal scale of the graphic display. 11. At the bottom of the Micrograph parameter page, set: "CHAN. a STORED INTO c AT EVERY SHOT" to 'YES' 12. To initialize these variables, turn the control voltage 'OFF' and then 'ON' again. 13. Briefly activate the manual selector switch for injection to activate the Micrograph display. 14. Now activate the manual selector switch associated with the analog output channel you wish to examine and the Micrograph will display the analog output graphically.

Remember to change the Micrograph parameter page and the P&V Control Parameter, 'To', back to their original values after you have completed your measurements. As well, you must turn the control voltage 'OFF' and then 'ON' to re-initialize the changed values.

336

7. ELECTRICAL SYSTEM.

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MAINTENANCE: 22.

TROUBLESHOOTING PROPORTIONAL VALVE CIRCUIT

This is a typical wiring diagram of a PA89 proportional valve circuit for machines with a single proportional speed valve Y1, and a single proportional pressure valve K1.

K1W1

Position Feedback

K1W2 K1W3 K1W3

K1 VALVE

K1K1+ OV E8/E16

0V K1 ELK0+

K+ ANALOG + 10000 mF/40V (PA88 only)

0V

Position Feedback

Y1W1 Y1W2 Y1W3 Y1W3

Y1 VALVE

Y1Y1+ 0V

OV E8/E16

Y1

Y+ ANALOG

ELK0+ 0V

+ 10000 mF/40V (PA88 only)

-24VC 0V 24VK

+24VK 0V

OV

Figure 7.35

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7. ELECTRICAL SYSTEM.

337

MAINTENANCE: Preventive Troubleshooting

It is always easier to troubleshoot a problem when you know what to expect normally. On the following pages, the steps are outlined to measure the normal signals that should be present on the proportional valve circuit. As well, space is provided for you to record those measurements. Measure and record the measurements and keep this information for future troubleshooting reference. Remember that valve calibrations may change some of these signals slightly, so keep this document as your original and record your measurements on a photocopy. Re-record the measurements after any valve calibrations. Step 1. Is the analog signal present ? •

Check for 0-10 Vdc at K1 for pressure or at Y1 for speed, while the valve is operating.

NOTE! There will always be a signal present during idling. Step 2. Is the amplifier output signal present ? •

On the dc scale, check for a voltage across K1- and K1+ for pressure, and across Y1and Y1+ for speed, while the valve is operating.

Step 3. Is the feedback transducer supply voltage present ? •

On the ac scale, check for the feedback transducer supply voltage across K1W1 and K1W3 (not shield) for pressure and across Y1W1 and Y1W3 (not shield) for speed. You should measure approximately 10 VAC.

Step 4. Is the feedback transducer signal consistent and stable ?

338

•

On the ac scale, check for a voltage across K1W2 and K1W3 for pressure and across Y1W2 and Y1W3 for speed, while the valve is operating.

•

As the valve function increases, pressure or speed, you should measure a increasing voltage. From minimum to maximum valve function, there will be a voltage spread of approximately 3/4 to 1 volt. For example, at 300 psi K-valve pressure to 2900 psi K-valve pressure you might see a spread of 5.3 V a.c. to 6.3 V a.c., respectively.

7. ELECTRICAL SYSTEM.

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MAINTENANCE: 22.1 HOW TO SET UP PRESSURE VALVE TEST 1.

Disconnect solenoid plug S25 from the ejector forward directional control valve. T

2.

On the EJECTOR screen page, set ejector forward speed V25 to 30 %.

3.

On the EJECTOR screen page, set ejector forward pressure P25 to various levels as set out below.

4.

Operate the MANUAL EJECTION switch to FORWARD and hold while the measurements are being taken.

5.

Using a multimeter, record the readings at each step.

NOTE! The ejector forward pressure is normally subject to a reduction factor (i.e. K0366 = 80%) Pressure - K1

Measure between

K1 & 0V(dc)

K1- & K1+(dc)

K1W2 & K1W3(ac)

idle

______

_____________

_______________

P25 - 10%

______

_____________

_______________

P25 - 20%

______

_____________

_______________

P25 - 30%

______

_____________

_______________

P25 - 40%

______

_____________

_______________

P25 - 50%

______

_____________

_______________

P25 - 60%

______

_____________

_______________

P25 - 70%

______

_____________

_______________

P25 - 80%

______

_____________

_______________

P25 - 90%

______

_____________

_______________

P25 - 100%

______

_____________

_______________

Measure between K1W1 & K1W3(AC) for the transducer supply voltage _________________

NOTE! This test is valid only if the ejector is controlled by the K-valve.If not, a different manual function must be employed.

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MAINTENANCE: HOW TO SET UP SPEED VALVE TEST 1.

Disconnect solenoid plug S25 from the ejector forward directional control valve.

2.

On the EJECTOR screen page, set ejector forward pressure P25 to 30%.

3.

On the EJECTOR screen page, set ejector forward speed V25 to various levels as set out below.

4.

Operate the MANUAL EJECTION switch to FORWARD and hold while the measurements are being taken.

5.

Using a multimeter, record the readings at each step.

NOTE! Ejector forward speed is not normally subject to a reduction factor (i.e. K0330 = 100%). Speed - Y1

Measure between

Y1 & 0V(dc)

Y1- & Y1+(dc)

Y1W2 & Y1W3(ac)

idle

______

_____________

_______________

V25 - 0%

______

_____________

_______________

V25 - 10%

______

_____________

_______________

V25 - 20%

______

_____________

_______________

V25 - 30%

______

_____________

_______________

V25 - 40%

______

_____________

_______________

V25 - 50%

______

_____________

_______________

V25 - 60%

______

_____________

_______________

V25 - 70%

______

_____________

_______________

V25 - 80%

______

_____________

_______________

V25 - 90%

______

_____________

_______________

V25 - 100%

______

_____________

_______________

Measure between Y1W1 & Y1W3(AC) for transducer supply voltage ____________

NOTE! Please note that this test is valid only if the ejector is controlled by the Y1 valve. If not, a different manual function must be employed.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: If the machine has a two pump hydraulic system, there will be two proportional speed valves. Measure and record those readings as well. There will be a second amplifier card to control the second proportional speed valve. In any event, the wiring termination points are as indicated below. Speed - Y2

Measure between

Y2 & 0V(dc)

Y2- & Y2+(dc)

Y2W2 & Y2W3(ac)

idle

______

_____________

_______________

V25 - 0%

______

_____________

_______________

V25 - 10%

______

_____________

_______________

V25 - 20%

______

_____________

_______________

V25 - 30%

______

_____________

_______________

V25 - 40%

______

_____________

_______________

V25 - 50%

______

_____________

_______________

V25 - 60%

______

_____________

_______________

V25 - 70%

______

_____________

_______________

V25 - 80%

______

_____________

_______________

V25 - 90%

______

_____________

_______________

V25 - 100%

______

_____________

_______________

Measure between Y2W1 & Y2W3(AC) for transducer supply voltage ____________

NOTE! This test is valid only if the ejector is controlled by the Y1 and Y2 valve. f not, a different manual function must be employed.

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341

MAINTENANCE: 22.2 TESTING CLAMP PROPORTIONAL VALVE FUNCTION Measurements of the analog output signals, to the valve, and the corresponding feedback signals, from the valve, are useful for checking the function of the proportional valve. On machines with separate amplifier cards measurement of the signal from the analog card to the amplifier card is also useful. The feedback signal indicates the position of the spool within the valve and therefore shows if the spool is actually moving in response to the output signal. Using a digital multimeter, take the measurements at the appropriate test points, as described below for the machine size and valve type. That section will also tell you what to expect when comparing output and feedback values. Measurements should be taken at 10% speed intervals, starting at 10% and ending at 100%, for both mold closing and mold opening.

CAUTION! TO PREVENT MOLD DAMAGE, CAUSED BY THE MOLD HALVES MAKING CONTACT AT HIGH SPEED, DURING CLAMP VALVE TESTING ON :DIRECT HYDRAULIC MACHINES.

The last 2 inches of mold closing should be at a reasonably slow speed. If V3 is used as the last closing speed (as on older machines) then it should not be increased along with V1 and V2 and it should come into effect at about 2 inches before mold close. If you have 5 step mold protection then V3 may be set the same as V1 and V2 but mold protection must be initiated at 2 inches and mold protection speeds must be reasonably low. TOGGLE MACHINES.

Manually increase the mold height so that the mold halves do not make contact.

342

7. ELECTRICAL SYSTEM.

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MAINTENANCE: CLOSING

Set speeds V1, V2 and V3 on the Mold Closing screen page to correspond with values in the speed column and measure and record the voltages while manually actuating the Mold Close switch. Remember to set speeds back to their original values after completing the testing.

Speed Settings

Output to Valve

Feedback Signal

10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 % OPENING

Set speeds V6, V7 and V8 on the Mold Opening screen page to correspond with values in the speed column and measure and record the voltages while manually actuating the Mold Open switch. Remember to set speeds back to their original values after completing the testing.

Speed Settings

Output to Valve

Feedback Signal

10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %

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MAINTENANCE: TEST POINTS AND THEIR LOCATIONS Machines up to and including 500 tons (with built-in amplifier card)

The test points for measurement are found on TB2 on the side of the card rack. The analog Output to the Valve is measured between terminals marked 0V and A05B. The Feedback Signal is measured between terminals CL (0 volt lead - gray) and CLR (feedback lead - blue). If the machine is equipped with a Bosch valve for injection then similar measurements may be taken to test that valve. The analog Output to the Valve is measured between terminals marked 0V and A06. The Feedback Signal is measured between terminals L (0 volt lead - gray) and IR (feedback lead - blue). The feedback should be approximately proportional to the output signal but opposite in polarity Machines up to and including 500 tons (with separate Bosch amplifier card)

The test points for measurement of the analog Output to the Valve are terminals marked 0V and A05, located on TB2, on the side of the solid state unit, or on the analog card. The test points for measurement of the Feedback Signals are found on TB2, on the side of the card rack. The valve supply voltage (plus/minus 15 volts) is also be measured at this position. The Feedback Signal for the main spool is measured between terminals YSW SIG and YSW 0. The feedback signal will be similar in magnitude and the same polarity as the output signal. The Feedback Signal for the pilot spool is measured between terminals YSH SIG and YSH 0 with the motor off. There will be a feedback signal range of approximately 2 - 3 volts to indicate minimum to maximum pilot spool movement. This signal is negative for clamp opening and positive for clamp closing. This signal indicates pilot spool movement only and does not readily compare to the output signal.

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7. ELECTRICAL SYSTEM.

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MAINTENANCE: Machines over 500 tons (with built-in amplifier card)

The test points for measurement of the Output to the Valve and Feedback Signal are on TB2, usually on the side of the card rack. The Output to the Valve is measured between terminals marked Y+ and 0V. The Feedback Signal for the main spool is measured between terminals marked FB and 0V.

15

14 13 12 11 10

9 8 7

6 5

FEEDBACK

4 3

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

9

10

OUTPUT TO VALVE (Y+) MOLD CLOSING

MOLD OPENING

The Output to the Valve is between 0 and -10V for mold closing and between 0 and +10V for mold opening. The Feedback Signal uses 9V as a null position. The signal range is 6V either side of the null and is opposite in polarity to the output. Therefore the feedback for mold closing will be between +9 and +15V and the feedback for mold opening will be between +9 and +3V.

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MAINTENANCE: Machines over 500 tons (with separate Rexroth amplifier card)

The signal from the analog card (terminal Y+) to the amplifier card is between 0 and -10V for mold closing and between 0 and +10V for mold opening.

0V

Spool Stroke Actual Value

black red

Set Value Measure the signal value voltage of plus/minus 6 volts at the set value test sockets. Plus/minus 6 volts corresponds proportionally to the plus/minus 10 volt signal sent from the analog card (terminal Y+). Measure the actual value voltage of plus/minus 6 volts at the actual value test sockets. The actual value voltage corresponds to the spool stroke. 6 5 4 3 2 1 0 -1 -2 -3 -4

FEEDBACK

-5 -6

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

9

10

OUTPUT TO VALVE (Y+) MOLD CLOSING

MOLD OPENING

The Feedback Signal uses 0V as a null position. The signal range is 6V either side of the null and is opposite in polarity to the set value. Therefore the feedback for mold closing will be between 0 and +6V and the feedback for mold opening will be between 0 and -6V.

346

7. ELECTRICAL SYSTEM.

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MAINTENANCE: 8. PNEUMATIC SYSTEM 1.

AIR SERVICE UNIT.

The air service unit comprises of two main parts: • Pressure Regulator. • Lubricator unit (Oil Mist). Pressure Regulator.

On a daily basis let out the condensation that has accumulated in the regulator, do not let the condensation rise above the maximum mark. To release the condensation squeeze the sides of the regulator tube as shown in figure 8.1.

ADJUSTING KNOB OIL REGULATING SCREW

OIL FILLER CAP PRESSURE REGULATOR

LUBRICATOR UNIT

FILTER ELEMENT

CONDENSATION RELEASE

Figure 8.1

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347

MAINTENANCE: When a noticeable drop in pressure is experienced, clean the filter element and bowl. Wash the filter element with a solvent such as petrol or paraffin, and then using compressed air blow through the filter from the inside out and allow to dry. Plastic items must only be washed in water and normal household detergent. Pressure settings.

Operating pressure is normally between 5 - 6 bar (73 - 87 psi). To set the pressure, turn the hand wheel anti clockwise to the end stops. Turn the hand wheel clockwise until the required setting is reached, lift the hand wheel to disengage before setting and then release. To lowering the pressure, turn the hand wheel anti clockwise until the pressure drops below the required level. Turn the hand wheel clockwise until the desired new value is reached.

2.

LUBRICATOR UNIT (OIL MIST).

Check the oil content in the bowl and top up if necessary, via the oil filler screw cap. Ensure that the oil siphon tube is always immersed in oil. Recommended oil: Viscosity approx.

15mm2/sec. at 50oC (max. 30 mm2/sec at 50oC)

Cleaning.

Use only water and normal household detergent. Setting the oil intake.

Turn then regulator screw clockwise until the end stop is reached. Turn the oil regulating screw a 1/4 turn anti clockwise. Check the oil intake in the sight glass to see if the oil is being supplied and adjust if necessary. Adjust the drip rate to suit the current application, turn the screw anti clockwise for more oil and clockwise for less.

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8. PNEUMATIC SYSTEM

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MAINTENANCE: 9. COOLING SYSTEM. 1.

HEAT EXCHANGER (OIL COOLER)

Corrosive action can occur in water type exchangers due to the chemical nature of the water used for cooling purposes. Deposits of limescale and rust formed by corrosion in the tubes of the heat exchanger reduce it's efficiency. Restricted and plugged passages hinder the flow of cooling water which prevents excess heat being carried away. Obstructed passages also permit corrosion to concentrate on tube walls. Corrosive action in some cases has caused leakage of water into the hydraulic fluid which loses its lubrication qualities causing excessive wear and loss of efficiency of the hydraulic components. Corrosive And Scale-Forming Water

In many areas of the country untreated water is hard and scale forming. Such waters should be treated to prevent damage to the heat exchanger, and to prolong periods between cleanings. It is strongly recommended that CLEAN SOFT WATER is used as the coolant in heat exchangers. Before piping water to a heat exchanger, it should be analyzed to determine what action it will have on the metals in the exchanger. Where a problem with water is known to exist, it is recommended that water treating specialist be consulted. If salt water must be used as a cooling medium, zinc pencils should be used as sacrificial anodes in the heat exchanger on the inlet side to help counteract electrolytic action between the salt water and the metal of tube walls. When these zinc pencils are employed they should be inspected periodically and replaced if deteriorated. Periodic Inspection

When the exchanger is first installed, data should be taken to ascertain temperature and pressure drops within the hydraulic system. This data recorded at regular intervals will help to indicate when there are any accumulation of sediment or scale. From such data the proper time interval between oil cooler cleanings can be established. If temperature and pressure drop data have not been compiled, it will be necessary to conduct periodic visual inspection of the heat exchanger to determine the extent of scale build up, and to determine when cleaning is required. When visual inspection or pressure and temperature data indicate that scale has built up in the heat exchanger, cleaning is required to help restore efficiency and to prevent damage that could occur to the system or heat exchanger. The screen used in the water strainer should also be inspected periodically and cleaned.

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9. COOLING SYSTEM.

349

MAINTENANCE: Cleaning Water Passages

Severely fouled water tubes can be cleaned by the use of a rotary brush similar to a shotgun cleaner in conjunction with an air or electric rotating tool. Cleaning Oil Passages

Formation of oil sludge and other deposits about the tubes decreases the efficiency of the exchanger and it is important that a cleaning medium is used which is suitable for removing such sludge. Benzol, trichloroethylene and other commercial solvents have been found to be effective in performing this operation. Benzol is highly inflammable, however, and must be used with great care. After first soaking in solvent for about ten minutes, the solvent should be circulated through the exchanger in the reverse direction to normal flow for approximately fifteen minutes. The length of time of circulation depends on the amount of dirt deposit.

WARNING! BEFORE INSTALLING THE EXCHANGER IN THE SYSTEM, ENSURE ALL THE SOLVENT HAS BEEN REMOVED.

If facilities for cleaning the heat exchanger are not available in the plant, it is recommended the exchanger be removed from the installation and sent to a local automobile radiator shop for cleaning. The water tubes should be pressure tested (125 PSI maximum) after cleaning to ensure that leakage into the oil chamber will not occur

CAUTION! ALWAYS FIT NEW GASKETS WHEN AN EXCHANGER HAS BEEN DISASSEMBLED FOR CLEANING. The water consumption of the machine depends very much on the cycle time, especially on the length of the injection and plasticizing sequence.

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9. COOLING SYSTEM.

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MAINTENANCE: The size of the oil cooler required is generally based on the following data: Ambient air temperature at maximum

-

86 °F

Reservior oil temperature at maximum

-

120 °F

Temperature of incoming water at maximum

-

85 °F

The incoming water supply should be able to provide: 28 - 100 Tons

8 GPM

150 - 200 Tons

12 GPM

250 Tons

14 GPM

300 - 450 Tons

19 GPM

This does not include additional water consumed by the mold and other cooling circuits. Single - pass design ( pure counterflow ) A

Multi - pass design A

B

A

B

A D

E E D

E

D C

A Screws E Bonnets

F

G

F

B Shell Tube

E C

C

C Gaskets

F Draining / Venting

F

G

F

C

D Zinc Sacrificial Anode G Inner Tubes

Figure 9.1

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351

MAINTENANCE:

352

9. COOLING SYSTEM.

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MAINTENANCE: 10. LUBRICATION SYSTEM 1.

OIL LUBRICATION

An important features on any machines is an effective lubrication system. Engel machines have a pre-measured central lubrication system consisting of: • Oil Reservoir • Electric Pump Motor • Distribution Injection • Impulse Generator • Pressure Sensor The central lubrication system supplies a predetermined amount of oil to various friction points on the injection molding machine. The amount of oil dispensed at the friction point is determined by the size of the dosing nipple which can vary from 0.01 to 1.5 cm3. The system is deemed a total loss system because none of the oil is return to the tank. The impulse generator controls the frequency of lubrication cycles. On Toggle lever machines, select the “Mold open” page, then F4 “Central lubrication” and set the Central lubrication count ZSZ as directed in the table below: Standard and Packaging machines recommended lubrication count ZSZ Clamp tonnage

Lubrication count

80 / 100

90

150 / 200

70

250 / 300

50

400 / 500

40

At the preselected time the electric pump motor supplies lubrication oil to the distribution injector which responds with a pressure increase. As soon as a preset pressure is reached (normally 12 bar or 25 bar depending on the system) the pump shuts off. Each individual spring-loaded injector on the distribution unit now displays a definite amount of lubrication oil to be distributed to the lubrication points. If the machine does not resume pressure to distribute the oil in 10 seconds or does not relieve the system to zero pressure within 5 seconds of shutting the motor off, the system will go into an alarm state. The following machine components are connected to the central lubrication system: 1. Toggle Mechanism 2. Moving Platen 3. Injection Unit (Old Type Machines) 4. Platen Support

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MAINTENANCE: The following machine components are connected to the manual lubrication system: 1. Mold Height Adjustment 2. Guide Bushing For Carriage 3. Toggle Guide The lubrication injectors are available in three sizes, numbered 3, 5 and 10. ES80 machines and up: • Toggle and Tie-Rods, use a number 5 injector. • Platen Support and Injection Unit use a number 3 injector. ES400 machines and up: • Platen and Toggles use a number 10 injector. • Platen Support and Injection Unit use a number 5 injector. Because of the importance of lubrication, a periodic check of the lubrication system and the lubrication lines is recommended.

354

10. LUBRICATION SYSTEM

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MAINTENANCE: Brook Hanson Electric Motor bearing re-lubrication. Machine up to 500 tons.

NOTE! Do not lubricate motors while in operation, grease will be forced through the bearings and into the motor before the grease is forced out of the drain. Grease accumulation on the motor windings will reduce insulation life. Check the motor name plate to determine the frame size. The table below lists the motor frame sizes, the frequency of lubrication and the amount of grease required for each bearing.

Frame Size Up to 286T 324T - 326T 364T 365T 405T 444T - 445T 504

Quantity of Grease per Bearing (grams) 0 23 26 33 40 45 45

Frequency of Lubrication Seal for Life 6 Months 6 Months 6 Months 6 Months 6 Months 6 Months

Lubrication procedure 1. Stop the motor. 2. Lock out the circuit breaker switch. 3. Clean the grease nipples and the area immediately around the grease nipples. 4. Remove the relief plug 5. Using a grease gun, add the quantity of grease as shown in the table, via the nipples. Use a lithium based grease, Esso Unirex N3 or similar. 6. Run the motor for ten minutes to expel any excess grease. 7. Replace the relief plug. Siemens Electric Motor bearing re-lubrication Machines over 500 Tons 4. Lubricate bearings every 6 months, or more often in high temperature situation, as follows:. 5. Stop the motor. 6. Lock out the circuit breaker switch. 7. Thoroughly clean pipe plugs and then remove from the housing. 8. Remove the drain plug(s). 9. Remove any hardened grease from the motor drains. 10. Add grease at the inlet, using a grease gun, until a small amount of new grease is forced out of the drain. 11. Remove any excess grease from the inlet and drain area, replace the inlet plugs. 12. Run the motor for half an hour. 13. Replace the drain plug(s).

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355

MAINTENANCE: 2.

GREASE LUBRICATION. GREASE FITTINGS 30 / 55 TON 2

2

4

3 1

1

4

Find # Location

No. of Fittings 2

Frequency of Lubrication

1

Electric Motor

3000 hours or 6 monthly which ever time occurs first.

2

Moving

Op. Side

2

Weekly

Platen

Non-Op. Side

2

Weekly

3

Injection Base

1

Bi Weekly

4

Screw Drive Motor

1

6000 hours or yearly which time ever occur first

NOTE! This information is to be used as a guide only. Due to on going design improvements, grease fittings may not be exactly as illustrated Some electric motors have “sealed for life” bearings, check the frame size against the table on page 3

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10. LUBRICATION SYSTEM

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MAINTENANCE: ES 85 & 100 N-D (A02) GREASE FITTINGS

7

6

7

6

4

2

8

Find #

2

1

3

9

10

Location

1

Injection Base

2

5

No. of Fittings

Frequency of Lubr.

1

Weekly

Moving Platen

Op. Side 2 Non-Op. Side 2

Weekly Weekly

3

Moving Platen Sliding Support

Op. Side 1 Non-Op. Side 1

Weekly Weekly

4

Toggle Crosshead

Op. Side 1 Non-Op. Side 1

Weekly Weekly

5

Screw Drive Motor

6

Cylinder Platen

Op. Side 2 Non-Op. Side 2

Monthly Monthly

7

Tie Bar Nut Retainer Run mold height max to min

Op. Side 2 Non-Op. Side 2

Monthly Monthly

8

Tie Bar Support

Op. Side 1 Non-Op. Side 1

Monthly Monthly

9

Roller Cabinet bearing

1

Monthly

10

Electric motor )Grease fittings not always installed)

2

3000 hrs / 6 months *

1

6000 hrs / 1 year 8

* which ever time occurs first

NOTE! This information is to be used as a guide only. Due to on going design improvements, grease fittings may not be exactly as illustrated Some electric motors have “sealed for life” bearings, check the frame size against the table on page 3

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357

MAINTENANCE: ES150 TO 500 GREASE FITTINGS 3 6

2

4 4

4

Find #

5

2

1

5

Location

No. of Fittings

Frequency of Lubr.

1

Electric Motor

Non-Op. Side 2

3000 hrs / 6 Monthly *

2

Injection Base Linear Bearing

Op. Side 2 Non-Op. Side 2

Monthly Monthly

3

Screw Stabilizer Bearing

Op. Side 2 Non-Op. Side 2

Monthly Monthly

4

Toggle Guide

Op. Side 7 Non-Op. Side 7

Monthly Monthly

5

Carriage Cylinder Rod Clevis

Op. Side 1 Non-Op. Side 1

Monthly Monthly

6

Screw Drive Motor

6000 hrs / Yearly *

* which ever time occurs first

NOTE! This information is to be used as a guide only. Due to on going design improvements, grease fittings may not be exactly as illustrated.

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10. LUBRICATION SYSTEM

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MAINTENANCE: ES 600 TO 3500 GREASE FITTINGS 3

4

5

1

6 11

2

7

9, 10

8

12

13

14

9, 10

8

OPERATOR SIDE

Find #

Location

Lubricant Frequency of Lubr.

1

Toggle Guides

Grease

Daily

2

Platen Supports

Grease

Daily

3

Mold Height Adjustment Grease Run mold height adjustment to ensure operational state

4

Cylinder platen

Grease

Daily

5

Toggle joints

Oil

Daily

6

Platen

Oil

Daily

7

Crosshead

Oil

Daily

8

Injection Base Tie Bars

Grease

Weekly

9

Swivel Cylinder

Grease

Monthly

10

Swivel Plate

Grease

Monthly

11

Carriage Rod

Grease

Monthly

12

Cylinder Support

Grease

Monthly

13

Injection Cylinder Turning Stop

Grease

3 Monthly

14

Pump Motor(s)

Grease

3000 hrs / 6 months

* which ever time occurs first

NOTE! This information is to be used as a guide only. Due to on going design improvements, grease fittings may not be exactly as illustrated

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359

MAINTENANCE: TIEBARLESS MACHINE GREASE FITTINGS 2

1

3

4

5 Find #

Location

5 No. of Fittings

Frequency of Lubr.

1

Moving Platen Rotary Link

Op. Side Non-Op. Side

1

Weekly Weekly

2

Injection Base

Op. Side Non-Op. Side

1 1

Weekly Weekly

3

Screw Drive motor

1

6000 hrs / Yearly *

4

Moving Platen Support

Op. Side Non-Op. Side

1 1

Weekly Weekly

5

Electric Motor

Non-Op. Side

1

3000 hrs/6 monthly *

* which ever time occurs first

NOTE! This information is to be used as a guide only. Due to on going design improvements, grease fittings may not be exactly as illustrated

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10. LUBRICATION SYSTEM

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MAINTENANCE: SHUTTLE TABLE MACHINE GREASE FITTINGS

4

1

2

5

3

1

Find #

Location

Right Side Left Side

No. of Fittings

Frequency of Lubr.

2 2

Weekly Weekly

1

Moving Platen

2

Front table

2

Weekly

3

Left side of machine, beside lubrication motor delivers grease to 8 points Run mold height adjustment to ensure operational state

1

Monthly

4

Mechanical safety

1

Monthly

5

Electric Motor

2

3000 hrs / 6 monthly *

6

Screw Drive motor

1

6000 hrs / Yearly *

* which ever time occurs first

NOTE! This information is to be used as a guide only. Due to on going design improvements, grease fittings may not be exactly as illustrated

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MAINTENANCE: ES55, 85, 125, 150, 200 and 300 TON ROTARY BRIDGE 4

2

8

2

1 4

5

3

7 6

6

Find #

1 2 3 4 5 6 7 8

Location

No. of fittings

Center of rotary table Injection Carriage Linear Bearings Moving Platen Linear Bearings Carriage Cylinder Rod Clevis Screw Stabilizer Bearings Injection unit levelling jacks Screw Drive Motor Rotary Table Bearing and Ring Gear

* which ever time occurs first

1 4 2 2 4 3 1 3 NOTE

Frequency of Lubrication / Amount

150 hrs / 5cc SEE NOTE Weekly Weekly Monthly Monthly Monthly 6000 hrs / Yearly * 6 Monthly / 3cc SEE NOTE Use Metalon Hi-Tech EP1.5 grease

NOTE! This information is a guide only, grease fittings may not be exactly as shown.

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MAINTENANCE: 2.1

HYDRAULIC OIL AND LUBRICANT COMPARISON

WARNING! ENGEL ADVISES THE USE OF NEW, CLEAN ZINC BASED OIL, TO ISO CODE 16/13, IN THEIR INJECTION MOLDING MACHINES. THIS LEVEL OF CLEANLINESS OR BETTER MUST BE MAINTAINED THROUGHOUT THE LIFE OF THE MACHINE. REFER TO ISO 4406 - HYDRAULIC FLUID POWER - FLUIDS - METHOD FOR CODING LEVEL OF CONTAMINATION BY SOLID PARTICLES. USE MINERAL BASED HYDRAULIC OIL (CONTAINING ZINC) WITH A VISCOSITY CLASS OF ISO VG 46 (AT 40 OC) RECOMMENDED IN THE TABLE BELOW. CONTACT ENGEL CONCERNING POSSIBLE WARRANTY ISSUES IF ZINC FREE (ASHLESS) HYDRAULIC OIL IS USED IN THE INJECTION MOLDING MACHINE OR FOR RECOMMENDATIONS OR ADVICE ON HYDRAULIC OIL CHOICE. THE USE OF RECYCLED OIL TO OPERATE AN ENGEL INJECTION MOLDING MACHINE WILL VOID THE WARRANTY OF THAT MACHINE.

2.2

TRABON AND VOGEL AUTOMATIC GREASE LUBRICATION

CAUTION! TRABON and VOGEL AUTOMATIC GREASE LUBRICATION DO NOT USE ANY GREASE SPECIFIED IN THE RECOMMENDED LUBRICANTS TABLE OVERLEAF, THESE ARE ONLY FOR THE MANUALLY OPERATED GREASE LUBRICATION SYSTEMS USE: “MOBILUX EP 023” with a viscosity grade of 000 (preferred) OR “CHEVRON DURA-LITH EP NLGI 000-viscosity grade (preferred) OR “MOBILITH SHC 007” with a viscosity grade of 00 (if preferred grease not available this will work) OR CHECK WITH YOUR SUPPLIER FOR AN EQUIVALENT EP GREASE WITH A VISCOSITY GRADE OF NLGI 000.

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MAINTENANCE: Recommended suppliers and products for North America

Manufacturer

Hydraulic Oil

Gear Oil (older m/c only)

Ashland Valvoline

AW20

Epcomp.100 X 18MD S1000

BP Oil Corp.

Turbinol HL-46

Energol GR-XP-C220

Castrol *!*

Tribol 943AW

Chevron

Hydraulic oil ISO AW 46

Central Lubrication (Oil)

Manual Grease Lubrication (lithium base)

Waylube W-30 Energrease LS EP2

EP Gear Compound EP 220 Tegra Synthetic 220

Way oil Vistac 68

Citgo Petroleum Citgo A/W 46

EP Compound 220

Sliderite 68

Exxon

Nuto H 46

Spartan EP220 (3)

Febis K68

Esso

Nuto H 46

Penoled EP 3

(53)

Fiske Bros.

Lubriplate HO-46

APG 90

Lubriplate *3V

E.F. Houghton.

Hydro-Drive HP-200 MP Gear Oil 90

Way Lubricant 297

A. Margolis & Sons

T.I.P. 100-20 7*

M.P.E.P. Gear Lube SAE 90

M.P. 307

Mobil

DTE 25

Lubrite HD 90 Mobilgear 630

Vactra 2 Vacuoline 1409

Mobillux EP2

Shell

Tellus T 46 Tellus 46

Omala 220

Tonna V 68 (33)

Alvania EP

Sunoco

Sunvis 832 WR

Lubeway 1754 Sunway 1180

Sunaplex 992 EP GR

Texaco

Rando HD46

Tower Oil & Techn. Co.

Universal Gear Lube Waylube 68 HD 90 Meropa 220 (3)

Dura-Lith EP 2 Ultiplex EP #2

Beacon EP2 Nebula EP2

Multifak EP 2

#95 Way & Gear Lube, #47 Way Lube Expr.Gear Lube HG 90

*!* = Only use with BOSCH RKP Pumps

NOTE! Engel recommended lubricants are shown shaded.

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MAINTENANCE: Grease and Lubrication Oil.

A high quality lithium thickened grease is recommended conforming to NLGI#2 - EP grade according to DIN 51818. The lithium based greases have a wide operating temperature range and repel water. For the central lubrication system a high quality non drip lubricant is recommended. Non drip oils have an additive which causes the oil to adhere to metal surfaces, preventing throw-off or dripping. This type of oil is ideal for applications where dripping or splashing oil has to be minimized or eliminated.

NOTE! Approval from the FDA may be required for the use of these non-drip oil, depending upon the nature of the product being manufactured. Mold height Motor. The following lubricants and greases are recommended for use with the mold height motor and gearbox. It is also recommended that different manufacturers oil and types of oil are not mixed. The units are delivered with Gear oil CLP ISO VG 220 installed unless otherwise specified. Vertical Clamp, Injection molding machines Center shaft and Table bearing and ring gear Use Metalon Hi-Tech EP 1.5 grease to lubricate the center of the rotary table and the rotary table bearings and ring gear. This grease is blue in color. Refer to the greasing instructions in the section entitled GREASE LUBRICATION on the ES55, 85, 125, 150, 200 and 300 TON ROTARY BRIDGE injection molding machine Lubricant Selection.

Lubricant Ambient Temp.

0 +40

Oil

Grease

Helical Gear Oil

Bearings

-15 +25

-30 +80

-30 +80

Viscosity DIN 51502

Gear oil CLP ISO VG 220

Gear oil CLP VG 100

Gear oil PGLP ISO VG 220

ARAL

DEGOL BG 220

DEGOL BG 100

DEGOL GS 200

ARALUB HL3

BP

ENERGOL GR

ENERGOL GPXP 100

ENERGOL SGXP 220

ENERGREASE LS3

CALYPSOL

HSR 220 (ISO)

HSR 100 (ISO)

H 443

ESSO

SPARTAN EP220

SPARTAN EP 100

BEACON 3

FUCH

RENEP COMPOUND 106

RENEP COMPOUND 103

RENOLIT FWA 160

MOBIL

MOBILGEAR 630

MOBILGEAR 627

MOBIL SHC 630

MOBILUX 3

SHELL

OMALA 220

OMALA 100

TIVELA WB

ALVANIA R3

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MAINTENANCE: VISCOSITY EQUIVALENTS

Grade System

Kinematic Viscosities cSt 40 oC

cSt 100 oC

800 40

ISO 680

Saybolt Viscosities

SAE SAE SUS SUS AGMA Engine oil Gear OIl 210 oF 100 oF 4000

8

200

600

3000

500 30 400 350 300 250

20

460

7

320

6

220

5

140

90 16

150 100 80

50 40

4

100

3

68

2

46

30

80W 20

90

1000

70

500

60

400

55

300 250

50

75W

32

45 150

5

22 15

1

2000 1800 1500 1250

200 6

20

85W

8 7

125

80

40

30

10 9

60

150

2500

100

50

200

150

10W

4

40

15

5W

100 90 70

10

10

55

Viscosities can be related horizontally only, e.g. the following oils have similar viscosities: ISO 460, AGMA 7 and SAE Gear Oil 140. The viscosity / temperature relationships are based on 95 VI oils and are usable only for mono grade engine oils, gear oils and other 95 VI oils. Crankcase oil and gear oils are based on 100o C viscosity. The "W" grades are classified on low temperature properties. ISO oils and AGMA grades are based on 40 oC viscosity.

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MAINTENANCE: 11. PREVENTIVE MAINTENANCE 1.

GENERAL PRECAUTIONS

Injection molding machines convert electrical energy into hydraulic energy and in the process tremendous forces are developed. This is particularly evident in the clamping mechanism and in the heated plastic. These machines are designed with safety in mind, however their potential for inflicting injury, if safety precautions are not observed, should never be underestimated.

WARNING! WHENEVER THIS MACHINE IS RUNNING, IT IS ESSENTIAL THAT ALL GUARDS ARE IN THEIR PROPER PLACE.

Guards are provided on the machine to protect the body from contact with moving parts and areas of high temperature.

WARNING! NO PERSON SHOULD REACH OVER, UNDER OR AROUND GUARDS WHILE MACHINE IS IN OPERATION.

The correct positioning of the guards should be checked before start-up. Movable guards are provided with switching devices to prevent operation of the machine with the guard removed. These switches or interlocks must be regularly (at start of shift) checked for effectiveness. Any problem with the operation of a switch must be corrected before the machine is run.

WARNING! SWITCHES AND INTERLOCKS MUST NEVER BE INTENTIONALLY DEFEATED.

Melted plastic is extremely hot and may be under high pressure. Blockages of semi-cooled plastic may occur and when freed, can release molten material with considerable force. Careful attention should be paid to the correct procedure for removing frozen plugs of plastic. Purging of hot runner molds is particularly hazardous, and purging of the barrel also releases hot plastic under some pressure. Great care must be taken when dealing with hot plastic material and the operator must have the purge guard in position and be wearing suitable protective equipment. The EMERGENCY STOP BUTTON or MOTOR STOP BUTTON are easily identifiable and accessible. It is essential that the motor be stopped at any time when a person has to reach into the mold space or toggle area for more than a few seconds. The motor should also be stopped for any manual work in the area of the feed throat and screw. High voltages are present on the machine, particularly in the area of the plasticizing barrel. The heater band wiring is quite exposed and is therefore more susceptible to damage. Care should be taken when working in close proximity to these wires.

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MAINTENANCE: Whenever damaged or broken wires or conduit, open electrical boxes and control panels or any other apparent electrical hazard is detected the machine should be stopped and the power shutoff at the main disconnect switch. Do not power up the machine until the problem has been rectified by a suitably qualified person.

WARNING! WHENEVER MAINTENANCE OR REPAIR WORK IS TO BE CARRIED OUT, THE DISCONNECT SWITCHES MUST BE TURNED TO THE "OFF" POSITION AND AN APPROVED LOCKOUT PROCEDURE IMPLEMENTED.

2. • • • •

• •

• •

SUGGESTED LOCKOUT PROCEDURE Alert the operator and supervisor. Identify all sources of residual energy. Before starting work, place padlocks on the switch, lever, or valve, locking it in the "off" position, installing tags at such locations to indicate maintenance in progress. Ensure that all power sources are off, and bleed off hydraulic or pneumatic pressure, or bleed off any electrical current (capacitance), as required to prevent accidental movement of machine components. Test operator controls. As an additional safeguard on vertical clamp machines, safety blocks should be placed so as to mechanically prevent the clamp from closing under it's own weight, even though it is electrically locked out. After maintenance is completed, all machine safeguards that were removed should be replaced, secured, and checked to be sure they are functioning properly. Only after ascertaining that the machine is ready to perform safely should padlocks be removed, and the machine cleared for operation.

Maintenance staff should strive to: • Maintain the equipment in such a manner so that it will operate uninterrupted for as long as possible. • Maintain the equipment in such a manner so that it will always operate at the highest possible efficiency. • Protect the equipment from dirt, dust, moisture, corrosion, electrical and mechanical overloads. • Maintain good records of maintenance work to establish maintenance priorities and needs. • The preventive maintenance program includes: • Inspection • Cleaning • Tightening • Adjusting and Lubricating • Keeping equipment dry

3.

CONTROLS MAINTENANCE

The main causes of trouble on electrical controls are loose or faulty connections caused by: 1. Carelessness 2. Heat in normal operation 3. Vibration

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MAINTENANCE: 4.

PREVENTIVE MAINTENANCE SCHEDULE NOTE:

Preventive maintenance actions listed here are checks to ensure that there are no obvious problems with the machine and are performed at the time periods stated below. Use whichever time occurs first. for example if 500 hours of running time occurs before one month, do the preventive maintenance at 500 hours.

NOTE

Each preventive maintenance schedule period contains tasks specific to that period, but also included are all the tasks from the previous periods.

NOTE

Scheduled oiling or greasing tasks form part of the preventive maintenance tasks, but are not listed here, refer to the lubrication information for each type of machine in chapter 10 of this manual.

1. 8 HOUR (START OF EACH SHIFT) or DAILY CHECKS

Hydraulic oil

Check oil level

Lubrication oil

Check all lubricating points for visible lubricating film (toggle levers, tie-rods and guides) check run and connections of all lubrication tubing. Refer to lubrication schedules in chapter 10 of this manual.

Grease

If sprue break is used, grease carriage

Safety equipment

Injection unit

see chapter 3 of this manual

Mold area

safety guards - security of panels -

Toggle area

mechanical dropbar

Hoses

Check condition, replace if necessary.

Compression fittings

Check tightness.

Pressure filter

Check visual clogging indicator (where fitted).

Pressure gauge

To prevent the gauge seizing, turn the gauge through one revolution and leave the gauge in a neutral position (0)

2. Every mold change

Inspect and clean platen faces. To clean platen faces, use a proprietary brand of mold degreaser and a plastic souring pad. To protect the mold, use a proprietary brand of mold protector/rust inhibitor (clear coat). Injection nozzle centering

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Check sprue-bearing alignment and adjust if required.

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MAINTENANCE: 3. 500 HOUR or MONTHLY CHECKS

Manifolds, directional valves, hoses and fittings.

Check for oil leakage, correct as required.

Excess lubrication oil containers

Empty the container.

Ventilator filters (cont. cabinet)

Clean or replace the filter.

Mold height adjustment

Toggle machines: Run mold height to minimum and maximum. This ensures that the movement is working and spreads the grease over the full extend of the adjustment.

4. 3000 HOUR or 6 MONTHLY CHECKS

Hydraulic oil quality

Send oil sample for analysis. (Recommended cleanliness should conform to ISO 4406 annex B - code 14/11 or better)

Machine calibration

Check calibration is within limits. (Chapter 4 of this manual)

All oil filters

Change.

Heat exchanger

If hard water (minerals or metals, held in suspension) is used, check for contamination blocking waterways. Remove build-up of minerals or metals with a proprietary descaler.

All limit switches

Confirm switching function. Does the operation of the limit switch(es) block the related function.

Electric pump motor(s)

Grease the motor, if required. See chapter 10 of this manual

Card rack and connections

Remove dust or other debris from the cards and ensure that all connections are tight.

Injection nozzle centering

Check sprue bearing alignment If no mold change in this time

5. 6000 HOUR or YEARLY CHECKS

Machine levelling

Verify machine level. Refer to chapter 11 paragraph 5

Moving platen support

Refer to paragraph 6

Platen parallelism

Verify platen parallelism. Refer to chapter 11 paragraph 11.7

Tie-bar stretch

Refer to chapter 11 paragraph 9

Barrel, Screw and Ring tolerances

Dismantle barrel to check condition and tolerances. Refer to chapter 11 paragraph 12 for tolerances

Thermocouple elements

Clean and inspect contact points

Motor/pump flexible coupling

Check condition and replace if necessary

Moving and Stationary platen

Re-tap mounting holes to ensure each mounting point is clear.

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MAINTENANCE: 5.

MACHINE CHECKS AND INSPECTIONS (SEMI - ANNUAL)

Preventive Maintenance Date:___________________ Machine Serial number ________________________ ES___________/___________Control type:________________

1. Safety Devices

Please indicate

Hydraulic interlock

____________

Electric switches E1 & E2

____________

Electric switches E3 & E4

____________

Mechanical drop bar

____________

Purge guard E9 & Carriage Swivel E52

____________

Clamp Plexiglass or Covers

____________

Emergency Stop function

____________

All cover installed

____________

All Warning Signs in place

____________

Condition of Gates, Rollers, Guides...

_____________

Additional comments: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________

It is recommended when performing the semi-annual and annual preventive maintenance checks that section 5 be photocopied and filled out as a permanent record of that machine history.

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MAINTENANCE: 2. Electric

Please Indicate

Incoming Supply Voltage

600 / 480 / 240 / 208 /

Transformer Voltages

480 / 240 / 120 / Voltage

Main Motor(s)

/

/ Amps full load

____ ____ Amps idle

1

2 3 Mold Height Motor

Contactors

_______

Overload(s) (Reset and Set)

_______

Breakers (Reset and Set)

_______

Fuses

_______

Connections, Solenoid Plugs (tight?)

_______

+/- DC Voltage supply

_______

Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

3. Temperatures

Barrel

_______

Nozzle

_______

Feedthroat

_______

Oil

_______

Auxilliary (verify accuracy with voltage generator)

_______

Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

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MAINTENANCE: 4. Hydraulic

Please indicate

Clean Suction Strainer and Magnet

_______

Change Pressure Filter(s)

_______

Pump

_______

Screw Drive Motor (rpm’s)

_______

Hoses

_______

Compression Fittings (tight?)

_______

Pressure Gauge (manual)

_______

Pressure Transducer

_______

Accumulator

_______

No Leaks

_______

Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

5. Mechanical

Cross Head Nuts (tight) Toggle Pins Casting Bolts Mold Height Gears Mold Height Brake Barrel Head (tight?) Nozzle (tight?) Stationary Platen Bolts (tight?) Tie Bar Nuts (tight?) Tie Bar Support Feet (tight?) Additional comments________________________________________________ __________________________________________________________________

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MAINTENANCE: 6. Nozzle alignment

Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

7. Machine Calibration

Strokes Speeds Pressure(s) Back Pressure Screw rpm Additional comments________________________________________________ __________________________________________________________________

8. Miscellaneous

Toggle Lubrication Unit and Hoses Air Filter(s) (Clean or Change) Electric Cabinet Fans Mold Height Function (E22 and E23) Test Mold Protection Pressure Tighten and Check Heater Bands Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

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MAINTENANCE: 9. Oil Sampling

Additional comments________________________________________________ __________________________________________________________________ Follow up suggested for these items: 1._______________________________________________________________ 2._______________________________________________________________ 3._______________________________________________________________ 4._______________________________________________________________ 5._______________________________________________________________

Final Summary

________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ _________________________________________________________________

Signed off by:___________________

Completed by:_____________________

Print Name:____________________

Print Name: _______________________

Date:_________________________

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Date Completed: ___________________

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MAINTENANCE: MACHINE CHECKS AND INSPECTIONS ANNUAL

Preventive Maintenance Date:___________________ Machine Serial number ________________________ ES___________/___________Control type:________________

Please indicate

1. Machine Levelling

(Verify within specifications only) Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

2. Moving Platen Support - Tie Bar Level

____________

(Verify within specifications only) Mold Open/Mold Closed Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

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MAINTENANCE: Please indicate

____________

3. Platen Parallelism

(Verify within specification only)

Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

4. Tie Bar Stretch

(Verify within specification only)

Additional comments________________________________________________ _________________________________________________________________ __________________________________________________________________

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MAINTENANCE: Please indicate 5. Lubricate Main Motor Bearings

_________

Additional comments________________________________________________ __________________________________________________________________

6. Remove dust from Control Cards (tighten external wiring connectors)

__________

Additional comments________________________________________________ __________________________________________________________________

7. Incoming Water Flow Check

_________

Temperature Additional comments________________________________________________ __________________________________________________________________

8. Clamp Tonnage Adjustment Function

Additional comments________________________________________________ __________________________________________________________________

9. Oil Sampling

Additional comments________________________________________________ __________________________________________________________________

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MAINTENANCE: Follow up suggested for these items:

1._______________________________________________________________ 2._______________________________________________________________ 3._______________________________________________________________ 4._______________________________________________________________ 5._______________________________________________________________ 6._______________________________________________________________ 7._______________________________________________________________ 8._______________________________________________________________ 9._______________________________________________________________ 10.______________________________________________________________

Final Summary

________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ _________________________________________________________________

Signed off by:___________________

Completed by:_____________________

Print Name:____________________

Print Name: _______________________

Date:_________________________

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Date Completed: ___________________

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MAINTENANCE: 6.

CHECKING AND ADJUSTING MACHINE LEVEL.

The operation of an injection molding machine that has not been correctly levelled causes mechanical stresses to the machine. This could lead to tiebar breakage, improper mold clamping, flashing of the mold, excessive wear on bushings and the toggle system, or roller bearing platen support breakage.

6.1

ADJUSTMENT OF MACHINE MOUNTS • •

• •

6.2

Use a precision machinist's level. Refer to chapter 4 paragraph 4.1 on machine levelling for single or split base machines. When making adjustments try to keep the space between the support plate and the mount housing to a minimum. Check machine level on both frame and tiebars. (See section on Moving Platen Roller Bearing Supports, for machines so equipped.) When the machine has been levelled, tighten the locknut.

EUROMAP 7 TEST BLOCK

This test block is used in conjunction with the tie-bar stretch checks and adjustments, a mold can be used but Engel recommends the use of a test block. The test block is a hollow cylinder in Fe 37 (or stronger) steel. The test block should be flange mounted on the stationary platen. Measurements of the test block (mm) Abbreviations: e1 = maximum clearance between tiebars da = outside diameter di = inside diameter h = height Table 11.2 Test Block e1 da 160 135 180 150 200 170 224 200 280 250 355 315 450 400 560 500 710 630 900 800 1120 1000

380

di 112 125 140 160 200 250 315 400 500 630 800

h 140 160 180 200 250 315 400 500 630 800 1000

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MAINTENANCE: 7.

CHECKING AND ADJUSTING MOVING PLATEN BEARING SUPPORT

To eliminate deflection of the tiebars as the mold is opening or closing, the larger machines (or when requested) have platen bearing supports. Moving platen bearing supports are particularly important with heavier molds or longer tiebars. The bearing travels along a wear plate to support the mold during the opening or closing function.

FIXED PLATEN

STATIONARY PLATEN

TIEBAR

B

7.1

WEAR PLATE

ADJUSTING SCREW AND LOCKNUT

A

MOVING PLATEN BEARING ADJUSTMENT

Ensure that the machine frame is level before commencing this procedure. Release the locknuts and loosen the adjusters, on both sides, retighten by hand. Mount a mold or test blocks to simulate the typical working weight that the platen would carry. Utilizing a 5 ton clamp force setting and maximum mold opening, position A, initiate an automatic mold height adjustment. Check the distance between the “wear” plate and the underside of the lower tie bar, on both sides, with dial gauge when the mold is almost closed, against readings with mold fully opened. The initial measurement is taken with the dial gauge as close to the stationary platen as permitted by the wear-plate retaining bracket. • Measure in front of the moving platen. • Measure behind the moving platen. • Measure at the back of the tie bars Adjust the moving platen support bearings for minimum deflection to achieve the same or as close as possible to the measurement at the stationary platen. The measurement should be within 10 – 15 thousandth of an inch.

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MAINTENANCE:

NOTE! Check the deflection on the tie bars every six months. Adjust to ensure that the weight of the moving platen and mold is supported and is not wearing the tie bars or the bushings in the moving platen. Repeat for the other side of the machine. When adjustment are satisfactorily completed, tighten all locking nuts. MOVING PLATEN

WEAR PLATE

LOCK NUTS

TIEBAR

Typical types of Platen bearing support adjustment

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MAINTENANCE: 8.

CHECKING PLATEN PARALLELISM.

NOTE! Check the deflection on the tie bars every six months. Adjust to ensure that the weight of the moving platen and mold is supported and is not wearing the tie bars or the bushings in the moving platen.

For preventive maintenance purposes, it is useful to keep track of platen parallelism. Any deviation beyond a certain allowed limit, could alert the maintenance technician to potentially serious mechanical problems. Significant deviation beyond the allowed limit could show up in the molding process as unexplained flash in one corner of the mold.

NOTE! If the parallelism is found to be beyond the maximum permissible deviation, Engel service should be contacted.

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MAINTENANCE: 9.

TIEBARLESS MACHINES - PLATEN PARALLELISM

The Tiebarless machine employes a flexible link on the moving platen to compensate for the flex in the clamping frame. Either a rotary link or a “flex-link” is used. The concept behind the use of flexible links is the same in both cases, and is described below for the rotary link case.

9.1

ROTARY LINK

Description:

The clamping frame is designed with a C frame base. The load carrying members have been sized to minimize clamp deformation under maximum clamping force. Although minimized, there is still some deformation, for which compensation must be made. The rotary link behind the moving platen and the special design of the platen support allow the moving platen to follow the deflection of the stationary platen and keep the mold faces parallel. The drawing below shows the clamp with the mold closed but before tonnage has been applied. Therefore, there is no deformation evident at this time and the platens are parallel.

The drawing below shows the clamp with the mold closed and tonnage applied. The top of the stationary platen has been pushed away from the vertical. However the moving platen has stayed parallel due to pivoting at the rotary link. The apparent tendency for shearing motion on the sealing surfaces of the mold is nullified by the bowing upwards of the clamp's bottom member. The moving platen's ability to actually lift off its support bearings also aids in this cause.

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MAINTENANCE: 9.2

ADJUSTMENTS FOR MAINTAINING PLATEN PARALLELISM:

The tiebarless machine is designed to allow the moving platen to deflect to follow the deflection of the stationary platen. The platens can therefore remain parallel. This deflection acts against two springs which are located, one on either side of the moving platen. The purpose of the springs is to return the moving platen to a parallel position when clamping pressure is released as the mold opens. The springs apply pressure to the lower half of the moving platen, thereby causing it to pivot about the rotary link. The pivoting motion is limited by two mechanical stops on the upper half of the moving platen. The pressure setting at the springs must be high enough to counteract the weight of the mold in addition to the resistance of the moving platen to pivot. Measurements to determine platen parallelism should be made between the inside faces of the moving and stationary platens. Take the measurement from each of the four corners (approximately one inch in from the edges) of the stationary platen to the corresponding corners of the moving platen. Make sure that the measuring device is perpendicular to the platen surfaces. No adjustments should be made to the return springs tensioning screws.

The screws are adjusted at the factory to ensure that the moving platen pivots back to the mechanical stops when clamping pressure is released.

NOTE! The STOP SCREW * is only fitted to the 60TL machines. After vertical parallelism adjustments have been completed, adjust and lock the stop screw at a gap of 0.040” (1mm) *. The stop screw is fitted to limit the degree of clockwise movement (as viewed from the operator side) of the platen pivot.

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MAINTENANCE: Parallelism Adjustment Procedure

Before attempting any platen parallelism adjustment, ensure that the machine is level. Check the machine level: 1. 2. 3. 4.

Using an engineers spirit level or a precision water level, check the level of the machine across and along the moving platen guide rails. Check the machine level along the injection unit guide rail. The machine must be level within 0.002 to 0.004 inches per foot. Adjust the spindle of the machine support, clockwise to raise or anti clockwise to lower, the machine as necessary to achieve a level situation.

For vertical parallelism: 1. Using an inside micrometer, measure between each corner of the stationary platen to the same position on the moving platen. 2. Loosen the locknuts on the mechanical stops, see the figure on the previous page. 3. Using an Allen key adjust the stops until the four corners are within the allowed tolerance of 0.002 inches of each other. If horizontal parallelism adjustment is required: 1. Remove the plastic screw covers in the two guide rails and loosen all the screws. 2. Move the platen forward to a position just short of the front guide rail screw hole. 3. Using a pry bar between the machine frame and the moving platen, adjust the horizontal parallelism to within 0.002 inches. 4. Tighten the front guide rail screw. 5. Move the platen backward to a position just short of the rear guide rail screw hole. 6. Using a pry bar between the machine frame and the moving platen, adjust the horizontal parallelism to within 0.002 inches. 7. Tighten the rear guide rail screw and then the remaining guide rail screws. 8. Check the parallelism again, at the following three positions: a) fully open b) a mid way position c) almost closed Re-adjust as required, following the procedure as before. 9. Re-install all screw hole covers and tighten the mechanical stop locknuts. Adhere to the torquing specifications for the guide rail mounting screws as listed below.

100 Ton Tiebarless

10 x M6 screws for each guide rail

(M6 Grade 12.9 = 11.28 ft lbs).

8 x M5 screws for each guide rail

(M5 Grade 12.9 = 6.63 ft lbs).

60 Ton Tiebarless 40 Ton Tiebarless

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11. PREVENTIVE MAINTENANCE

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MAINTENANCE: 9.3

“FLEX – LINK”

Adjustments for Maintaining Platen Parallelism:

The clamping frame is a C frame design. The load carrying members have been sized to minimize clamp deformation under maximum clamping force. Although minimized, there is still some deformation, for which compensation must be made. The specially designed flex- link on which the moving platen is mounted allows the moving platen up to two degrees of "flex” to follow the deflection of the stationary platen. The movement of the moving platen with the stationary platen allows the seal between the two mold halves to be maintained. The platens can therefore remain parallel. The flex-link is also spring loaded to ensure platen parallelism at various mold weights. The spring returns the moving platen to a parallel position when clamping pressure is released as the mold opens. The pivoting motion is limited by a mechanical stop on the upper half of the moving platen. Measurements to determine platen parallelism should be made between the inside faces of the moving and stationary platens. Take the measurement from each of the four corners (approximately one inch in from the edges) of the stationary platen to the corresponding corners of the moving platen. Ensure that the measuring device is perpendicular to the platen surfaces. Parallelism Adjustment Procedure

Before attempting any platen parallelism adjustment, ensure that the machine is level. Check the machine level: Using an engineer’s spirit level or a precision water level, check the level of the machine across and along the moving platen guide rails. Check the machine level along the injection unit guide rail. The machine must be level within a tolerance of between 0.002” to 0.004” per foot. Adjust the spindle of the machine support, clockwise to raise or anti clockwise to lower the machine as necessary to achieve a level situation. Adhere to the torque specifications for all the mounting screws as listed below.

BOLT SIZE M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

16/12/05

TORQUE (Nm) 9 15 37 75 130 320 640 1120 2294 3850

TORQUE (ft-lbs) 7 11 27 54 94 232 463 810 1660 2840

11. PREVENTIVE MAINTENANCE

387

MAINTENANCE: For Vertical Parallelism: 1. Move the clamp to minimum mold height. 2. Using an inside micrometer, measure between each corner of the stationary platen to the same position on the moving platen (approx. 1” in from the edge). The platens must be parallel within the allowed tolerance of 0.002” (0.05mm). 3. To adjust the parallelism, loosen the two lock bolts at the bottom of the moving platen. 4. Using the “adjusting nut” move the bottom of the platen either in or out to achieve parallelism. 5. Move the clamp to 95% of maximum mold height and recheck the parallelism, adjust as required. 6. Once the platens are parallel (within tolerance), tighten the lock bolts. 7. Adjust the pivot stop so that there is 0.004” (0.1mm) between the stop and the platen.

WHEN THE PARALLELISM HAS BEEN SET ADJUST GAP TO BE 0.004”

PIVOT STOP

MIN. MOLD HEIGHT

4000.4355

LOCK BOLT ADJUSTING NUT

SPRING

95% OF MAX. MOLD HEIGHT

STATIONARY PLATEN ADJUSTMENT

SHOWING THE FLEXLINK AND ADJUSTMENT POINTS

388

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MAINTENANCE: 10.

TOGGLE MACHINES.

10.1 CHECKING PARALLELISM AND TIE BAR STRETCH

NOTE! Parallelism and tie bar stretch should be done together, as they are interrelated. Do not adjust the tie bar nuts under tonnage. 10.1.1

PLATEN PARALLELISM

The deviation from parallel is the difference between the largest and the smallest measurements taken at four equidistant points between the platens. Test Procedure

The distance between the inside faces of the platens is measured from at least 4 equidistant points around an imaginary circle of diameter dm (see table 11.3). Ensure that the measuring device is perpendicular to the platen faces.

DETERMINE CIRCLE DIAMETER FROM TABLE 11.3

MEASUREMENT POINTS "X" ARE POINTS ON CIRCLE NEAREST TIE-RODS

STATIONARY PLATEN

MOVING PLATEN

NOTE! Always take the measurements on the forward movement

Using an inside micrometer or dial gauge check platen parallelism at points on platen as shown in the figure above and compare with the permissible deviation allowed in Table 11.3 on the next page.

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MAINTENANCE: Table 11.3. Permissible Deviation Allowed

Type and Clamp force ES28 (H) ES30 ES45 (H) ES55 (H) ES50 (A) ES80 (A) ES85 ES100 ES125 ES150 ES175 ES200 ES225 ES250 ES300 ES400 ES450 ES550 ES725 ES800 ES1000 ES1200 ES1600

Circle Diameter Horizontal (e1) Vertical (e1) (dm) 260 260 351 260 260 351 305 305 435 305 305 435 346 346 476 346 346 476 346 346 476 346 346 476 420 420 580 420 420 580 460 460 670 460 460 670 534 458 744 534 458 744 560 560 820 660 660 920 660 660 920 800 800 1140 900 900 1350 1000 1000 1450 1100 1100 1550 1100 1100 1550 1400 1400 1980

Between Tie Bars

Between Tie Bars

Perm. Dev. Perm. Dev. (mm) (inches) 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.15 0.15 0.15 0.15 0.15 0.15 0.20 0.20 0.20 0.20 0.25 0.25 0.25 0.25 0.25

e1

Distance between tie bars - Horizontal/Vertical

dm

Measuring circle diameter

Perm. dev.

Permissible deviation at minimum and maximum clamp force.

10.1.2

0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.006 0.006 0.006 0.006 0.006 0.006 0.008 0.008 0.008 0.008 0.010 0.010 0.010 0.010 0.010

ADJUSTING PLATEN PARALLELISM

Operate the mold height key switch to the “increase” position and increase the mold height and close the clamp until the toggle can be locked up without the test blocks or mold halves touching. • With mold height key switch, decrease the mold height until test blocks or mold are approximately 1/16 th of an inch apart. • Remove the rear cover to expose the ends of the four tiebars. • Completely remove the three ring gear retainers. (See fig. 11.9) • Loosen the three Allen screws on the tie bar retaining plates (4). (See fig. 11.9) • Pull the ring gear off the tie bar nuts. (See fig. 11.9)

390

11. PREVENTIVE MAINTENANCE

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MAINTENANCE: • Use a pry bar to wind all tie bar nut gears in, to close the mold or test blocks together so the mold is closed but not under tonnage. • The tie bar nuts are adjusted, in combination with the platen support bearing, to achieve platen parallelism and are also used to adjust the correct tie bar stretch. • In the “Set up” mode, open and close the clamp until the mold or test blocks are almost touching (1/16th of an inch). • Always take the measurements on the forward movement. • Using a suitable inside micrometer or dial gauge check platen parallelism at points on platen as shown on page 397 and compare with the permissible deviation allowed in Table 11.3. • Adjust the tie bar nuts to increase or decrease mold height until the platens are parallel. Use a pry bar to wind the tie bar nut gear in or out. One tooth equals approximately 0.0015” or 0.03mm of movement. • Continued checking or adjustment of the moving platen bearing is required in order to achieve platen parallelism. • Replace the ring gear on the tiebar nuts, the nuts may have to be adjusted slightly to get the teeth to align, but do not replace the ring gear retainers.

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11. PREVENTIVE MAINTENANCE

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MAINTENANCE: 10.2 TIE BAR STRETCH It is important to check the tiebar stretch at least once a year. This will guarantee that the machine is producing its rated tonnage and that the four tiebars are stretching equally. This will also ensure that the machine is not being abused by over clamping which could lead to broken tiebars. 10.2.1

CLAMP FORCE CALCULATION (METRIC & IMPERIAL)

The actual clamp force on toggle clamps can be very quickly calculated by means of the physical tiebar stretch L MOVING PLATEN TIEBAR ADJUSTMENT NUT TIEBAR

L

STATIONARY PLATEN

CF D

MHT BASE

L

METRIC

IMPERIAL

Mp (Megapond)

CF = Clamping Force

lbs

L = Measuring Length

mm

ins

L = Tiebar stretch

mm

ins

E = Modulus of elasticity for steel A = Cross-sectional Area of Tiebar

2

6

2100 Mp/cm

MHT = Moldheight

30x10

psi

cm 2

ins 2

cm

ins

A4500060

CF =

LxExAx4 L

A=

d2 2

L=

FxL ExAx4

1 U.S. ton = 2000 lbs

392

11. PREVENTIVE MAINTENANCE

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MAINTENANCE: 10.2.2 1. 2.

CHECKING TIEBAR STRETCH

Remove the machine's rear cover to expose the four tiebars. Mount accurate measuring gauges to the end of each tiebar. The bottom tiebars can be measured using magnetic gauge holders attached to the machine frame. The upper tiebars can be measured using magnetic gauge holders attached to rigid supports mounted to the machine frame, as shown in the figure below.

NOTE! Ensure that measurement gauges are mounted perpendicular to tiebar surface. Rear and fixed operator side safety shield removed

Rigid support attached to machine frame

3.

Set all measuring gauges to zero.

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MAINTENANCE: 4.

5. 6.

7.

In set-up mode, activate the mold close selector switch to bring the two mold halves together. Minimum clamp pressure is required to eliminate slack in the toggle mechanism. Wait until the toggle mechanism relaxes before zeroing the measuring gauges. In manual mode, clamp up the machine under full tonnage. Ensure that "P1" is set to 100% and that full tonnage is being produced. If the machine is not equipped with a clamp force transducer, adjust the mold-height until the toggle just barely toggles up. Read and record the tiebar stretch of each tiebar and determine if the correct amount of tiebar stretch is being produced.

Refer to tables 11.4 and 11.5 for tiebar stretch specifications. If the machine is over clamping, reduce 'P1' pressure to avoid tiebar breakage. Example: A tiebar stretch is to be done on a 150 Ton machine with a measured length 'L' of 70" The tiebar stretch (∆ L) = F x L / E x A x 4 F= 300 000 lbs. (150 Tons x 2000 lbs/Ton) L= 70 inches E= 30 000 000 psi A= 6.849 square inches ∆ L = 300,000 x 70 / 30,000,000 x 6.849 x 4 = 21,000,000 / 821,880,000 = .0255512 inches (0.65 mm) For this example, you would be looking for 26 thousandths of an inch (0.65 mm) tiebar stretch.

394

11. PREVENTIVE MAINTENANCE

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MAINTENANCE: 10.2.3

TIE BAR STRETCH CALCULATION.

The table below enables Tie Bar stretch to be calculated as follows: • Select "A" multiplication factor from Tie Bar diameter. • Enter "B" Clamp Force required (normally nominal clamp force of machine). • Enter "C" Measuring length (see fig. 11.8). • Insert numbers for A, B and C into formula to derive D the tie Bar stretch. AxBxC=D

Tie Bar Diameter (mm) 45 50 60 75 85 90 100 130 140 155 170 180 220 240 265 330 360

16/12/05

A

B

C

D

Multiplication Factor x 10 -9 6805 5512 3828 2450 1907 1701 1378 815 703 574 477 425 285 239 196 127 106

Clamp Force (U.S. Tons)

Measured length (mm)

Tie Bar Stretch (mm)

200 250 300

2240 2230 2745

0.854 0.948 1.135

11. PREVENTIVE MAINTENANCE

395

MAINTENANCE: 10.2.4

ADJUSTING TIEBAR STRETCH

If the tiebars are stretching unequally, tiebar breakage could result. The tiebars should be adjusted to the tolerance shown, for the appropriate machine size, in the chart on the following page. The diagram below shows the mold-height adjustment area of the machine.

TIEBAR NUT (4) TIE BAR NUT RETAINING PLATES (4)

RING GEAR RETAINER MOLDHEIGHT ADJUSTMENT GEAR

A4500065

MOLD HEIGHT MOTOR

To adjust the stretch of an individual tiebar, a qualified maintenance technician must: •

Remove the rear panel covering the mold height motor and ring gear.

•

Set up the dial gauge indicators as shown in the section “Checking tie-bar stretch”

•

Check the tie-bar stretch as described in the section “Checking tie-bar stretch”.

•

Check the platen parallelism and make a note of the readings as a reference.

•

Remove the gear retainers.

•

Loosen the tie-bar nut retaining plates to hand tightness.

NOTE! It is not necessary to completely remove the Mold Height Adjustment Gear.

396

11. PREVENTIVE MAINTENANCE

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MAINTENANCE: •

Pull the ring gear off the nut to be adjusted, ensuring that the gear is still on the other three nuts. Use a pry bar to adjust the tie-bar nut, turn the nut 1 tooth at a time.

•

If one tiebar is stretching more than the others, always adjust the tiebar nut to reduce the stretch of the out of tolerance tiebar.

Tie bar nut

Ring gear Pry bar

•

The tiebars are right-hand thread, adjusting the tiebar nut counterclockwise (ccw) will reduce the tiebar stretch.

•

Repeat the instructions, in the section “Checking Tiebar Stretch" until all four tiebars are within the desired tolerance.

•

Check the platen parallelism in conjunction with the “Tiebar stretch” and ensure that the parallelism is within tolerance.

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MAINTENANCE: Table 11.4 TIEBAR STRETCH (Metric) TYPE

CF MP

ES28 ES30-ND ES45 ES50(T) ES55-ND ES80(T) ES85-ND ES100 ES100ND ES125 ES150 ES175 ES200 ES225 ES250 ES300 ES400 ES450 ES500 ES550 ES725 ES750 ES880 ES1000 ES1200 ES1250 ES1300 ES1400 ES1500 ES1600 ES1800 ES2000 ES2500 ES3200 ES3500

25 30 41 45 50 73 77 91 91 114 136 159 182 205 227 273 364 409 453 500 659 750 800 1000 1200 1250 1179 1400 1360 1600 1800 1813 2500 3200 3171

CF TBR DIA MHT (MIN) MHT (MAX) ML (MIN) ML (MAX) STR (MIN) STR (MAX) TBR Stress STR/Tooth TOL

398

(MP) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (KPa) (mm) (mm)

TBR DIA (mm) 45 45 50 60 50 60 60 60 60 75 75 85 85 90 90 100 140 140 140 155 170 170 180 220 240 240 220 265 240 265 265 265 330 360 360

MHT MIN (mm) 150 150 147 150 150 150 150 150 150 150 150 150 150 200 200 200 300 300 300 310 400 400 400 400 400 400 400 400 400 500 500 800 700 800 1000

MHT MAX (mm)

ML MIN (mm)

ML MAX (mm)

380

1279

1509

380 430 380 430 480 480 533 533 550 550 610 864 864 864 800 920 920 1000 1200 1200 1400 1200 1400 1400 1250 1250 1600 1800 2000 2000

1279 1270 1279 1270 1690 1690 1857 1857 1880 1880 2335 2853 2853 2853 3325 3737 3737 4001 4426 4426

1509 1550 1509 1550 2020 2020 2240 2240 2230 2230 2745 3417 3417 3417 3815 4257 4257 4601 5226 5226

5955

6705

STR MIN (mm) 0.000 0.000 0.000 0.245 0.000 0.392 0.412 0.490 0.557 0.517 0.621 0.620 0.708 0.720 0.800 0.965 0.787 0.889 0.990 1.049 1.292 1.292 1.497 1.386 1.398

2.057

STR MAX (mm) 0.000 0.000 0.000 0.289 0.000 0.462 0.504 0.578 0.594 0.618 0.742 0.748 0.854 0.854 0.948 1.135 0.965 1.067 1.194 1.203 1.472 1.472 1.722 1.637 1.650

2.316

TBR Stress KPa 400 471 521 402 637 643 681 804 805 643 772 701 801 804 893 868 578 650 772 662 726 726 786 658 663 691

STR/ tooth (mm) N/A N/A N/A 0.050 N/A 0.050 test 0.050 test 0.053 0.053 0.053 0.053 0.053 0.053 0.053 0.076 0.076 0.076 0.070 0.067 0.067 0.060 0.100 0.100 test

635

test

725 816

0.143 test

731 786

test test

Tol. (mm) N/A N/A N/A 0.015 N/A 0.020 0.020 0.025 0.025 0.025 0.030 0.030 0.035 0.035 0.040 0.045 0.045 0.050 0.050 0.060 0.060 0.075 0.070 0.070

0.100

Clamp Force Tiebar Diameter Minimum Mold-height Maximum Mold-height Minimum Measuring Length Maximum Measuring Length Minimum Tiebar Stretch Maximum Tiebar Stretch Tiebar Stress Stretch per Tooth of Adjustment Tolerance of measurements (max/min) based on 5% of max. clamp force

11. PREVENTIVE MAINTENANCE

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MAINTENANCE: Table 11.5 TIEBAR STRETCH (Imperial) TYPE

CF (U.S. Tons) ES28 28 ES30-ND 33 ES45 45 ES50(T) 50 ES55-ND 55 ES80(T) 80 ES85-ND 84 ES100 100 ES100ND 100 ES125 125 ES150 150 ES175 175 ES200 200 ES225 225 ES250 250 ES300 300 ES400 400 ES450 450 ES500 500 ES550 550 ES725 725 ES750 750 ES880 880 ES1000 1100 ES1200 1320 ES1250 1375 ES1300 1300 ES1400 1540 ES1500 1500 ES1600 1760 ES1800 1980 ES2000 2000 ES2500 2750 ES3200 3520 ES3500 3500 CF TB DIA MHT (MIN) MHT (MAX) ML (MIN) ML (MAX) STR (MIN) STR (MAX) TB Stress STR/Tooth

16/12/05

TBR DIA (In) 1.772 1.772 1.969 2.362 1.969 2.362 2.362 2.362 2.362 2.953 2.953 3.346 3.346 3.543 3.543 3.937 5.512 5.512 5.512 6.102 6.693 6.693 7.087 8.661 9.449 9.449 8.660 10.433 9.450 10.433 10.433 10.433 12.992 14.173 14.173

(US-TONS) (In) (In) (In) (In) (In) (In) (In) (PSI) (In)

MHT MIN (In) 5.91 5.91 5.79 5.91 5.91 5.91 5.91 5.91 5.91 5.91 5.91 5.91 5.91 7.87 7.87 7.87 11.81 11.81 11.81 12.20 15.75 15.75 15.75 15.75 15.75 15.75 15.75 15.75 15.75 19.69 19.69 31.50 27.56 31.50 39.37

MHT MAX (In) 14.96 18.90 14.96 14.96 16.93 14.96 16.93 18.90 18.90 20.98 20.98 21.65 21.65 24.02 34.00 34.00 34.00 31.50 36.22 36.22 39.37 47.24 47.24 55.12 47.24 55.12 55.12 49.21 49.21 63.00 70.87 78.74 78.74

STR MIN (In) 0.000 0.000 0.000 50.4 59.4 0.010 0.000 50.4 59.4 0.015 50 61 0.016 50.4 59.4 0.019 50 61 0.022 66.5 79.5 0.020 66.5 79.5 0.024 73.1 88.2 0.024 73.1 88.2 0.028 74.0 87.8 0.028 74.0 87.8 0.031 91.9 108.1 0.038 112.34 134.53 0.031 112.34 134.53 0.035 112.34 134.53 0.039 130.9 150.2 0.041 147.1 167.6 0.051 147.1 167.6 0.051 157.5 181.1 0.059 174.3 205.7 0.055 174.3 205.7 0.055 0.000

STR MAX (In) 0.000 0.000 0.000 0.011 0.000 0.018 0.020 0.023 0.023 0.024 0.029 0.029 0.034 0.034 0.037 0.045 0.038 0.042 0.047 0.047 0.058 0.058 0.068 0.064 0.065 0.013

TB Stress PSI 5801 6831 7551 5827 9233 9323 9871 11654 11668 9321 11189 10163 11614 11655 12950 12587 8382 9430 10478 9606 10526 10526 11396 9536 9616 10016

0.000

0.012

9201

0.081 0.000

0.091 0.011

10516 11830

0.000 0.000

0.015 0.018

10596 11396

ML MIN (In)

234.4

ML MAX (In)

264.0

STR/ Tooth (In)

0.0020 N/A 0.0020 0.0020 0.0020 test 0.0021 0.0021 0.0021 0.0021 0.0021 0.0021 0.0021 0.0030 0.0030 0.0030 0.0028 0.0026 0.0026 0.0024 0.0039 0.0039

0.0056

Tol. (In.) N/A N/A N/A 0.0006 N/A 0.0008 0.0008 0.0010 0.0010 0.0012 0.0012 0.0014 0.0014 0.0016 0.0018 0.0018 0.0020 0.0020 0.0024 0.0024 0.0030 0.0027 0.0027

0.0040

Clamp Force Tiebar Diameter min. Mold-height max. Mold-height min. Measuring Length max. Measuring Length min. Tiebar Stretch max. Tiebar Stretch Tiebar Stress Stretch per Tooth of Adjustment

11. PREVENTIVE MAINTENANCE

399

MAINTENANCE: 11.

PLASTICIZING UNIT

MANUFACTURING TOLERANCES

NOTE! The measurement checks of the internal diameter of the barrel are made from the nozzle end, back to the feed throat area. Table 11.6 Manufacturing Tolerances - Barrel

diameter (mm)

Barrel Diameter MAXIMUM (mm)

Barrel Diameter MINIMUM (mm)

Barrel Diameter MAXIMUM (Inches)

Barrel Diameter MINIMUM (Inches)

18

18.018

18.000

0.7094

0.7087

22

22.021

22.000

0.8670

0.8661

25

25.021

25.000

0.9851

0.9843

30

30.021

30.000

1.1819

1.1811

35

35.025

35.000

1.3789

1.3780

40

40.025

40.000

1.5758

1.5748

45

45.025

45.000

1.7726

1.7717

50

50.025

50.000

1.9695

1.9685

55

55.030

55.000

2.1665

2.1654

60

60.030

60.000

2.3634

2.3622

70

70.030

70.000

2.7571

2.7559

80

80.030

80.000

3.1508

3.1496

85

85.035

85.000

3.3478

3.3464

90

90.035

90.000

3.5447

3.5433

105

105.035

105.000

4.1352

4.1339

120

120.035

120.000

4.7258

4.7244

135

135.040

135.000

5.3165

5.3149

150

150.040

150.000

5.9071

5.9055

160

160.040

160.000

6.3008

6.2992

170

170.040

170.000

6.6945

6.6929

400

11. PREVENTIVE MAINTENANCE

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MAINTENANCE: Table 11.7 Manufacturing Tolerances - Screw

NOTE! These tolerances relate to a GENERAL PURPOSE THERMOPLASTIC screw

diameter (mm)

Screw Diameter Screw Diameter MAXIMUM (mm) MINIMUM (mm)

Screw Diameter Screw Diameter MAXIMUM (Inches) MINIMUM (Inches)

18

17.900

17.800

0.7047

0.7008

22

21.900

21.800

0.8622

0.8583

25

24.900

24.800

0.9803

0.9764

30

29.900

29.800

1.1772

1.1732

35

34.900

34.800

1.3740

1.3701

40

39.900

39.800

1.5709

1.5669

45

44.900

44.800

1.7677

1.7638

50

49.900

49.800

1.9646

1.9606

55

54.800

54.700

2.1575

2.1535

60

59.800

59.700

2.3543

2.3504

70

69.800

69.700

2.7480

2.7440

80

79.800

79.700

3.1417

3.1378

85

84.800

84.700

3.3385

3.3346

90

89.750

89.600

3.5335

3.5315

105

104.750

104.600

4.1240

4.1181

120

119.750

119.600

4.7146

4.7087

135

134.700

134.500

5.3031

5.2953

150

149.700

149.500

5.8937

5.8858

160

159.700

159.500

6.2874

6.2795

170

169.500

169.300

6.6732

6.6653

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MAINTENANCE: Table 11.8 Manufacturing Tolerances - Ring

diameter (mm)

Ring Diameter Ring Diameter MAXIMUM (mm) MINIMUM (mm)

Ring Diameter Ring Diameter MAXIMUM (Inches) MINIMUM (Inches)

18

17.994

17.983

0.7084

0.7080

22

21.993

21.980

0.8659

0.8653

25

24.993

24.980

0.9840

0.9834

30

29.993

29.980

1.1808

1.1803

35

34.991

34.975

1.3776

1.3770

40

39.991

39.975

1.5744

1.5738

45

44.991

44.975

1.7713

1.7707

50

49.991

49.975

1.9681

1.9675

55

54.990

54.971

2.1650

2.1642

60

59.990

59.971

2.3618

2.3611

70

69.990

69.971

2.7555

2.7548

80

79.990

79.971

3.1492

3.1485

85

84.928

84.874

3.3440

3.3415

90

89.928

89.874

3.5405

3.5383

105

104.928

104.874

4.1310

4.1289

120

119.880

119.858

4.7197

4.7188

135

134.915

134.852

5.3116

5.3091

150

149.915

149.852

5.9022

5.8997

160

159.915

159.852

6.2959

6.2934

170

169.800

169.700

6.6850

6.6811

402

11. PREVENTIVE MAINTENANCE

16/12/05

MAINTENANCE: Table 11.9 Manufacturing Tolerances - Clearance

NOTE! These tolerances relate to a GENERAL PURPOSE THERMOPLASTIC screw. The measurement checks of the internal diameter of the barrel are made from the nozzle end, back to the feed throat area.

dia (mm)

Clear. Barrel/ Screw MAX (mm)

Clear. Barrel/ Screw MIN (mm)

Clear. Barrel/ Screw MAX (in)

Clear. Barrel/ Screw MIN (in)

Clear. Barrel/ Ring MAX (mm)

Clear. Barrel/ Ring MIN (mm)

Clear. Barrel/ Ring MAX (in)

Clear. Barrel/ Ring MIN (in)

18

0.218

0.100

0.0086

0.0039

0.035

0.006

0.0014

0.0002

22

0.221

0.100

0.0087

0.0039

0.041

0.007

0.0016

0.0003

25

0.221

0.100

0.0087

0.0039

0.041

0.007

0.0016

0.0003

30

0.221

0.100

0.0087

0.0039

0.041

0.007

0.0016

0.0003

35

0.225

0.100

0.0088

0.0039

0.050

0.009

0.0020

0.00035

40

0.225

0.100

0.0088

0.0039

0.050

0.009

0.0020

0.00035

45

0.225

0.100

0.0088

0.0039

0.050

0.009

0.0020

0.00035

50

0.225

0.100

0.0088

0.0039

0.050

0.009

0.0020

0.00035

55

0.330

0.200

0.0130

0.0079

0.059

0.010

0.0023

0.0004

60

0.330

0.200

0.0130

0.0079

0.059

0.010

0.0023

0.0004

70

0.330

0.200

0.0130

0.0079

0.059

0.010

0.0023

0.0004

80

0.330

0.200

0.0130

0.0079

0.059

0.010

0.0023

0.0004

85

0.335

0.200

0.0132

0.0079

0.161

0.072

0.0063

0.0028

90

0.435

0.250

0.0171

0.0098

0.161

0.072

0.0063

0.0028

105

0.435

0.250

0.0171

0.0098

0.161

0.072

0.0063

0.0028

120

0.435

0.250

0.0171

0.0098

0.177

0.120

0.0070

0.0047

135

0.540

0.300

0.0212

0.0118

0.188

0.085

0.0074

0.0033

150

0.540

0.300

0.0212

0.0118

0.188

0.085

0.0074

0.0033

160

0.540

0.300

0.0212

0.0118

0.188

0.085

0.0074

0.0033

170

0.740

0.500

0.0291

0.0197

0.340

0.020

0.0134

0.0079

16/12/05

11. PREVENTIVE MAINTENANCE

403

MAINTENANCE: CRITICAL WEAR

Repair or replace Cylinder and/or Screw when the combined wear of SCREW and BARREL is equal to or more than twice the maximum tolerance of the one specified by the OEM (see MANUFACTURING TOLERANCES). The machine is designed to meet the codes required by the original purchaser. If the machine is re-located, responsibility for conformation to codes of the new area will not be assumed by ENGEL. It is the responsibility of the user to create safe operating conditions on and around the machine. A detailed safety section and suggested machine safety checklists are included in the Controller Operator Manual.

404

11. PREVENTIVE MAINTENANCE

16/12/05

MAINTENANCE: 12. GENERAL TROUBLESHOOTING FLOWCHARTS The Trouble Shooting Flow Charts are designed to guide maintenance personnel through logical steps in fault finding when a problem occurs in one of the following areas.

NOTE! When a fault indication is based on an indicator it is assumed that the indicator has been checked to ensure that the lamp is not faulty.

Card Rack Power Supply Troubleshooting. - - - - - - - - - - - - - - - - - - - - - - - - - 404 Digital Inputs Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 405 Digital Outputs Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 407 Analog Inputs Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 409 Analog Outputs Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 410 Amplifier Card - Pressure Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - 411 Amplifier Card - Speed Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - 412 Machine Error Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 413 System Error Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 414 Ebias Error Trouble Shooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 414

16/12/05

12. GENERAL TROUBLESHOOTING FLOWCHARTS

405

MAINTENANCE:

A +/- 24 Vdc Power Supply Problem Exists

Does the 3-phase voltage exist at power supply primary taps?

POWER SUPPLY VAC to +/- 24VDC

No

Troubleshoot the 3-phase voltage supply to the power supply primary taps

Yes

Do all +/- 24vdc voltages appear at the secondary power supply taps?

No

Check primary and secondary wiring terminals are tight. Replace power supply.

Yes

Do all +/- 24 vdc voltages appear at card rack?

No

Check all +/- 24 vdc switching contacts and breakers

Yes +/- 24 vdc Power Supply Troubleshooting Complete

Figure 12.4 Card Rack Power Supply Troubleshooting.

406

12. GENERAL TROUBLESHOOTING FLOWCHARTS

16/12/05

MAINTENANCE:

Digital Input Problem Exists

Is the 24vdc power supply voltage present?

DIGITAL INPUTS

No

Refer to section on troubleshooting power supply

Yes

Is the 24VE supply voltage present?

No

Check VE supply voltage breaker

Yes

Is the VE supply available to the input device?

No

Check lead at VE supply located on the left side of the card rack - TB2

Yes

Is the input device operating correctly mechanically?

No

Replace input device

Yes

Next Page

Figure 12.5 Digital Inputs Trouble Shooting.

16/12/05

12. GENERAL TROUBLESHOOTING FLOWCHARTS

407

MAINTENANCE:

Previous Page

Is the digital input present at the digital input card?

No

Check wiring from input device to the digital input card

Yes

Is digital input LED lit ?

No

Replace digital input card

No

Replace digital input card

Yes

See "Steps to examine digital inputs" Controller Maintenance Manual

Is the digital input recognized by the CPU?

Yes

Digital Input Troubleshooting Complete

Figure 12.6 Digital Inputs Trouble Shooting (Continued).

408

12. GENERAL TROUBLESHOOTING FLOWCHARTS

16/12/05

MAINTENANCE: DIGITAL OUTPUTS Digital Output Problem Exists.

Is the digital output activated by the CPU?

See "Steps to examine digital outputs" Controller Maintenance Manual No

Does a machine error appear?

Does an Ebias error appear?

No

Yes

No

Yes

Does a System error appear? Yes

Yes

Refer to machine error listing.

Is the card supplied with 24 volts VK?

No

Refer to Ebias error listing.

Refer to System error listing.

Investigate the 24 volt VK supply.

Yes

Does the digital output LED activate?

No

Replace digital output card.

Yes

Does the digital output appear at the output terminal?

No

Replace digital output card.

Yes

Next Page

Figure 12.7 Digital Outputs Trouble Shooting.

16/12/05

12. GENERAL TROUBLESHOOTING FLOWCHARTS

409

MAINTENANCE:

Does the digital output appear at the solenoid plug?

No

Check wiring from digital output card to solenoid plug.

Yes

Is the resistance across the solenoid 18 - 25 ohms?

No

Replace solenoid.

Yes

Digital Output Troubleshooting Complete

Figure 12.8 Digital Outputs Trouble Shooting (Continued).

410

12. GENERAL TROUBLESHOOTING FLOWCHARTS

16/12/05

MAINTENANCE:

Analog Input Problem Exists

Does the transducer supply voltage from the analog card exist?

ANALOG INPUTS

No

Replace analog card

Yes

Does the analog card supply voltage reach the transducer?

No

Check and/or replace transducer cable and all connections

Yes

Is the feedback signal present and within expected range?

No

Replace transducer

Yes

See "Steps to examine analog inputs" Controller Maintenance Manual

Is the analog feedback signal recognized by the CPU?

No

Replace analog card

Yes

Analog Input Troubleshooting Complete

Figure 12.9 Analog Inputs Trouble Shooting.

16/12/05

12. GENERAL TROUBLESHOOTING FLOWCHARTS

411

MAINTENANCE:

Analog Output Problem Exists

See "Steps to examine analog outputs" Controller Maintenance Manual

Is the analog output activated by the CPU?

ANALOG OUTPUTS

No

Does an Ebias error appear?

No

Yes Yes

Does the analog output appear at the relevant output channel?

Yes

Refer to Ebias error listing

No

Does a System error appear?

Refer to System error listing

Replace analog card

Yes

Does the analog output appear at the valve amplifier card, or valve plug, if so equipped?

No

Check and/or replace wiring and all connections

Yes

Analog Output Troubleshooting Complete

Figure 12.10 Analog Outputs Trouble Shooting.

412

12. GENERAL TROUBLESHOOTING FLOWCHARTS

16/12/05

MAINTENANCE: Proportional Pressure Problem Exists

See "Troubleshooting Proportional Valve Circuit" Controller Maintenance Manual

Is the analog output

AMPLIFIER CARD PRESSURE (PA88/PA89)

No

signal present at terminal K1?

Refer to analog output Troubleshooting

Yes

Is the amplifier output signal present across K1- and K1+?

No

Check wiring connections and/or replace amplifier card

Yes

Is the 10 12 vac feedback supply voltage present across K1W1 and K1W3?

No

Check wiring connections and/or replace amplifier card

Yes

Does the ac feedback signal across K1W2 and K1W3 indicate stable valve operation?

No

Check wiring to feedback transducer and/or replace K - valve

Yes

Amplifier Card (Pressure) Troubleshooting Complete

Figure 12.11 Amplifier Card - Pressure Trouble Shooting.

16/12/05

12. GENERAL TROUBLESHOOTING FLOWCHARTS

413

MAINTENANCE:

Proportional Speed Problem Exists

See "Troubleshooting Proportional Valve Circuit" Controller Maintenance Manual

Is the analog output signal present at terminal Y1 and/or Y2?

AMPLIFIER CARD SPEED (PA88/PA89)

Refer to analog No

output troubleshooting

Yes

Is the amplifier output signal present across Y1- and Y1+ (Y2- and Y2+ for 2nd channel)?

No

Check wiring connections and/or replace amplifier card

Yes

Is10 -12VAC feedback supply voltage present across Y1W1 & Y1W3 Check 2nd channel?

No

Check wiring connections and/or replace amplifier card

Yes

Does AC feedback signal across Y1W2 and Y1W3 indicate stable valve operation?

No

Check wiring to feedback transducer and/or replace Y - valve

Yes

Amplifier Card (Speed) Troubleshooting Complete

Figure 12.12 Amplifier Card - Speed Trouble Shooting.

414

12. GENERAL TROUBLESHOOTING FLOWCHARTS

16/12/05

MAINTENANCE:

Machine Error Exists

MACHINE ERROR

Will the manual/automatic mode select switch reset the error state?

Refer to numerical error listing in the controller operator manual, chapter 6, to resolve

No

Yes

Has the error state, or condition causing the error message, been resolved?

No

Correct problem before re-starting cycle. Beware of lubrication error messages.

Yes

Re-start Automatic/ Semi-Automatic Cycle

Figure 12.13 Machine Error Trouble Shooting.

16/12/05

12. GENERAL TROUBLESHOOTING FLOWCHARTS

415

MAINTENANCE: System Error Appears On First Screen Page

Will turning the control voltage off and on again reset the error?

SYSTEM ERROR

No

Refer to system error listing in the Controller Maint. Manual, chapter 6, to resolve

Yes

Re-start Manual, Automatic or Semi-Automatic Cycle

Figure 12.14 System Error Trouble Shooting.

Ebias Error Appears On First Screen Page

Will turning the control voltage off and on again reset the error?

EBIAS ERROR

No

Refer to system error listing in the Controller Maint. Manual, chapter 6, to resolve

Yes

Re-start Manual, Automatic or Semi-Automatic Cycle

Figure 12.15 Ebias Error Trouble Shooting.

416

12. GENERAL TROUBLESHOOTING FLOWCHARTS

16/12/05

MAINTENANCE: REVISION LIST DATE Y. M. D

NATURE OF REVISION

ORIGINAL PAGE #

REVISED PAGE #

00 - 5 - 4

Re-issue in Framemaker format

00 - 5 - 4

Added “ISO” coding for oil cleanliness

163 - 165 & 231

163 - 165 & 231

00 - 5 - 4

Added “Castrol Tribol 943AW” to list of oil suppliers

165 & 231

165 &231

00 - 8 - 23

Added note for closed loop machines

286

286

00 - 11- 24

Change recommended hydraulic oil to VG46 and removed all references to VG48 and VG68

Front, 163, 164, 165, 321

Front, 163, 164, 165, 321

01 - 4 - 24

Re-Issue in Framemaker 5.5 + SGML format with revisions

all chapters

up-dated

01 - 5 - 24

Complex machine - personal injury hazard warning

Front

Front

01 - 5 - 24

Added warning concerning working in situations where hot plastic material may be a hazard to personnel

01 - 9 - 19

Added notes regarding Zinc free hydraulic oil.

Front, 183, 183 and 343

Front, 183, 184 and 343

01 - 11 - 22

Removed two tasks from Daily periodic maintenance

199

199

2002-04-26

Added caution about grease used in Trabon automatic lubrication system

343

343

2002-04-26

Added Shell Tellus 46 to list of recommended oils

343

344

2002-10-03

Added split base installation instructions, levelling and centering for old and new style Tiebarless machines

117 - 131

2002-10-03

Added notes in chapter 4 at various location advising not to use the vibration mounts to lift the machine.

Various chapter 4

2002-10-03

Filtroil gauge information update

201

2003-01-06

Ammended tolerance tables for Barrel, screws and rings

394 to 397

394 to 397

2003-01-06

Revised chapter 12 table of contents

399

399

2003-01-06

Figure 11.4 “L” revised to be the same for all sizes

388

388

2003-01-17

Revise Tiebar stretch and platen parallelism info

2003-01-17

Revise notes concerning lifting machines by mounts

Various chapter 4

Various chapter 4

2003-08-22

Added recommended lubricant for automatic lub system

361

361

16/12/05

REVISION LIST

378 to 398

417

MAINTENANCE: DATE Y. M. D

NATURE OF REVISION

ORIGINAL PAGE #

REVISED PAGE #

2003-09-11

Revised tiebar stretch and platen parallelism procedure for toggle machines

Various chapter 11

Various chapter 11

2003-09-11

Added “In-line” injection unit swivelling information

152

2003-09-11

Added Vertical clamp machine - nozzle height adjustment

154

2003-09-11

Added Vertical clamp machine - levelling

130

2005-12-12

Added Clampforce transducer LG99 information

333

418

REVISION LIST

16/12/05