Operating Manual Demag Modular 125/ - Demag Modular 800/: English [PDF]
OPERATING MANUAL Demag modular 125/475 – Demag modular 800/1120 English BA027.01.1.en Forward Customer Service-Extens
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OPERATING MANUAL Demag modular 125/475 – Demag modular 800/1120 English BA027.01.1.en
Forward
Customer Service-Extension Nos. / Address In order to assist you more quickly, the Service Department has been divided into different service teams. The telephone number or address of your relevant Service Team can be found in the list. Abroad
Germany
Team
Team
Team
Team
Team
International
West
Süd– West
Süd
Ost
+49–(0)911 / ...
0911 / 5061– ...
034672 / 97– ...
Spare Parts Sales
5061306
300
302
304
410
Technical Service Request for Service Engineer
5061307
301
303
305
411
Fax
500081
250
484
485
425
Address
Demag Ergotech GmbH Altdorfer Strasse 15
Demag Ergotech GmbH Werk Wiehe
90563 Schwaig
Donndorfer Strasse 3
Deutschland
06571 Wiehe Deutschland
For technical enquiries or orders for spare parts the machine type and serial number is required. Please have your operating manual handy for any technical enquiries. Machine Type
Demag modular
Machine Number
– Year of manufactur
2005
BA027.01.1.en
I
Forward
The injection moulding machine should be used for a discontinuous production of parts, preferably from macromolecular thermoplastic material.
A prerequisite for perfect machine operation is a sound knowledge of how the individual components function, and how to handle and maintain the machine. In this respect, this operating manual should prove a valuable aid. It informs you of the correct usage of your Demag Ergotech Injection Moulding Machine, and should be made available to all machine-setter. Please study this machine manual thoroughly before putting your machine into operation. Particular attention should be paid to text preceded by the symbol. It contains information which also concerns your safety. Note: – pay particular attention Attention! – Safety Information The descriptions and diagrams given in this operating manual correspond to the production series. We stress that this is subject to alterationin the case of customization or further technical developments. Reprinting or duplication of all or part of this manual, including extracts, requires our authorization. Passing on such copies or reprints to a third party is not permitted.
II
BA027.01.1.en
Table of contents
Note: A detailed table of contents can be found at the beginning of each chapter.
1
2
Technical Data 1.1
Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.2
Mould Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-60
Commissioning and Dismantling 2.1
Cable Suspension Diagrams and machine weights . . . . . . . . . . . . . . . . . . . . .
2-1
2.2
Off–loading, preservative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2.3
Installation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
2.4
Foundation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16
2.5
Installation and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-28
2.6
Flexible anti–vibration Machine Mounts (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-39
2.7
Connecting the Cooling Water Supply – Water Cooling . . . . . . . . . . . . . . . . . .
2-40
2.8
Filling with Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-53
2.9
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-55
2.10
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-69
BA027.01.1.en
I
Table of contents
3
4
5
II
Safety 3.1
General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3.2
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
3.3
Hydraulic Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
3.4
Electrical Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
3.5
Checking the Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18
3.6
Moveable Guard for the Mould Area – Operator Side/ pneumatically actuated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19
3.7
Dangers from Tie Bar removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21
3.8
Fire fighting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21
4.1
Operation general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.2
The Ergocontrol Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4.3
Program– and Data–disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
4.4
Page Layout, Release of Operating and Access Level . . . . . . . . . . . . . . . . . .
4-21
4.5
Description of the Screen Pages and their Operation . . . . . . . . . . . . . . . . . . .
4-25
Operation
Setting–up, Additional Equipment and Optional Equipment 5.1
Prewarming of Hydraulic Oil and monitoring of Hydraulic Oil . . . . . . . . . . . . .
5-1
5.2
Clamping Unit – SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
5.3
Injection Units – IU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15
5.4
Interfacing and Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-86
BA027.01.1.en
Table of contents
6
Maintenance 6.1
Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.2
Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2
6.3
Lubrication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4
6.4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5
6.5
Automatic Central Oil Lubrication of Clamping Unit . . . . . . . . . . . . . . . . . . . . .
6-13
6.6
Oil Change Motortraverse injection unit IU 11500 – IU 16000 . . . . . . . . . . . .
6-15
6.7
Hydraulic Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16
6.8
Changing the tank ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-19
6.9
Cleaning Oil Suction Filter 1FT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-20
6.10
Cleaning High Pressure Oil Filter 1FT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-24
6.11
Changing of Filter Bypass–Filter and extraction of test oil . . . . . . . . . . . . . . . .
6-26
6.12
Testing the hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-31
6.13
Maintenance for the electrical screw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-33
6.14
Servicing the Electric Motor – pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-44
6.15
Replacing a battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-45
6.16
Cleaning – De–scaling the Water Cooling System . . . . . . . . . . . . . . . . . . . . . .
6-47
6.17
Maintenance/Cleaning of Screw Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-51
6.18
Cleaning the screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-55
6.19
Cleaning the Screw Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-57
6.20
Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-59
6.21
Cleaning the inspection panels on the safety guarding . . . . . . . . . . . . . . . . . .
6-61
BA027.01.1.en
III
Table of contents
7
8
IV
Fault Elimination, Fault Messages 7.1
Fault Elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.2
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
Function Number Index 8.1
Function Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8.2
Function Numbers – Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
8.3
Function Numbers – Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9
BA027.01.1.en
Table of contents
1
1
Technical Data 1.1
Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.1.1
Data Sheet Demag modular 125/475 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.1.2
Data Sheet Demag modular 150/475 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
1.1.3
Data Sheet Demag modular 150/500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9
1.1.4
Data Sheet Demag modular 200/500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-13
1.1.5
Data Sheet Demag modular 200/560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-17
1.1.6
Data Sheet Demag modular 250/560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-21
1.1.7
Data Sheet Demag modular 250/630 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-25
1.1.8
Data Sheet Demag modular 300/630 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-29
1.1.9
Data Sheet Demag modular 350/710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-33
1.1.10
Data Sheet Demag modular 350/810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-37
1.1.11
Data Sheet Demag modular 420/800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-41
1.1.12
Data Sheet Demag modular 420/810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-45
1.1.13
Data Sheet Demag modular 500/900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-49
1.1.14
Data Sheet Demag modular 650/1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-53
1.1.15
Data Sheet Demag modular 800/1120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-57
1.2
Mould Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-60
1.2.1 1.2.1.1 1.2.1.2 1.2.1.3
Mould mounting dimensions Demag modular 125/475 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 125/475: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 125/475: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 125/475: EUROMAP layout . .
1-60 1-60 1-61 1-62
1.2.2 1.2.2.1 1.2.2.2 1.2.2.3
Mould mounting dimensions Demag modular 150/475 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 150/475: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 150/475: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 150/475: EUROMAP layout . .
1-63 1-63 1-64 1-65
1.2.3 1.2.3.1 1.2.3.2 1.2.3.3
Mould mounting dimensions Demag modular 150/500 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 150/500: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 150/500: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 150/500: EUROMAP layout . .
1-66 1-66 1-67 1-68
BA027.01.1.en
I
1
II
Table of contents
1.2.4 1.2.4.1 1.2.4.2 1.2.4.3
Mould mounting dimensions Demag modular 200/500 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 200/500: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 200/500: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 200/500: EUROMAP layout . .
1-69 1-69 1-70 1-71
1.2.5 1.2.5.1 1.2.5.2 1.2.5.3
Mould mounting dimensions Demag modular 200/560 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 200/560: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 200/560: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 200/560: EUROMAP layout . .
1-72 1-72 1-73 1-74
1.2.6 1.2.6.1 1.2.6.2 1.2.6.3
Mould mounting dimensions Demag modular 250/560 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 250/560: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 250/560: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 250/560: EUROMAP layout . .
1-75 1-75 1-76 1-77
1.2.7 1.2.7.1 1.2.7.2 1.2.7.3
Mould mounting dimensions Demag modular 250/630 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 250/630: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 250/630: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 250/630: EUROMAP layout . .
1-78 1-78 1-79 1-80
1.2.8 1.2.8.1 1.2.8.2 1.2.8.3
Mould mounting dimensions Demag modular 300/630 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 300/630: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 300/630: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 300/630: EUROMAP layout . .
1-81 1-81 1-82 1-83
1.2.9 1.2.9.1 1.2.9.2 1.2.9.3
Mould mounting dimensions Demag modular 350/710 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 350/710: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 350/710: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 350/710: EUROMAP layout . .
1-84 1-84 1-85 1-86
1.2.10 1.2.10.1 1.2.10.2 1.2.10.3
Mould mounting dimensions Demag modular 350/810 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 350/810: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 350/810: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 350/810: EUROMAP layout . .
1-87 1-87 1-88 1-89
1.2.11 1.2.11.1 1.2.11.2 1.2.11.3
Mould mounting dimensions Demag modular 420/800 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 420/800: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 420/800 : SPI layout . . . . . . . . Mould mounting dimensions Demag modular 420/800: EUROMAP layout . .
1-90 1-90 1-91 1-92
1.2.12 1.2.12.1 1.2.12.2 1.2.12.3
Mould mounting dimensions Demag modular 420/810 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 420/810: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 420/810: SPI layout . . . . . . . . . Mould mounting dimensions Demag modular 420/810: EUROMAP layout . .
1-93 1-93 1-94 1-95
BA027.01.1.en
Table of contents
1
1.2.13 1.2.13.1 1.2.13.2 1.2.13.3
Mould mounting dimensions Demag modular 500/900 . . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 500/900: DIN layout . . . . . . . . . Mould mounting dimensions Demag modular 500/900 : SPI layout . . . . . . . . Mould mounting dimensions Demag modular 500/900: EUROMAP layout . .
1.2.14 1.2.14.1 1.2.14.2 1.2.14.3
Mould mounting dimensions Demag modular 650/1000 . . . . . . . . . . . . . . . . . . 1-99 Mould mounting dimensions Demag modular 650/1000: DIN layout . . . . . . . . 1-99 Mould mounting dimensions Demag modular 650/1000 : SPI layout . . . . . . . 1-100 Mould mounting dimensions Demag modular 650/1000: EUROMAP layout . 1-101
1.2.15 1.2.15.1 1.2.15.2 1.2.15.3
Mould mounting dimensions Demag modular 800/1120 . . . . . . . . . . . . . . . . . . Mould mounting dimensions Demag modular 800/1120: DIN layout . . . . . . . . Mould mounting dimensions Demag modular 800/1120 : SPI layout . . . . . . . . Mould mounting dimensions Demag modular 800/1120: EUROMAP layout .
BA027.01.1.en
1-96 1-96 1-97 1-98
1-102 1-102 1-103 1-104
III
Technical Data
1
Technical Data
1.1
Data Sheets
1.1.1
Data Sheet Demag modular 125/475
Model description
1
Demag modular 125/475 – 320 Demag modular 125/475 – 440 Demag modular 125/475 – 610
International size code
1250 – 320 1250 – 440 1250 – 610
Clamping unit
1250
Clamping force
kN
1250
Locking force
kN
1375
Max. mould opening stroke
mm
450
Min. mould mounting height
mm
230
Max. mould mounting height
mm
460 (560
with WA)
Max. daylight between platens
mm
910 (1010
with WA)
Overall size of platens
hxv
mm
690 x 660
Daylight distance between tie bars
hxv
mm
475 x 450
Max mould weight
kg
1100
Max weight content on moving platen
kg
730
Ejection stroke
mm
140
Ejection force
kN
59
Ejector retraction force
kN
29
Hydraulic Ejector
BA027.01.1.en
1-1
1
Technical Data
Data Sheet Demag modular 125/475 – continued Injection unit
320
Screw cylinder Screw diameter
mm
L / D – Ratio
30
35
40
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
124
168
220
g
110
150
200
Shot weight in (PS) Max. metering stroke
mm
175
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
12.6
Hopper capacity
Ltr.
70
7.9
General Data
8.3
11.7
125/475 – 320
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
3 0 / 38***
3 0 / 38***
34 / 42***
1,85s–332mm / 1,85s–332mm
Net weight (without oil)
kg
6300
Machine dimensions L x W x H
m
4.9* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-2
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 125/475 – continued Injection unit
440
Screw cylinder Screw diameter
mm
L / D – Ratio
35
40
45
20
20
20
Injection pressure (at 400 C)
bar
2423
1855
1466
Cylinder head volume
cm3
177
231
293
g
160
210
260
Shot weight in (PS) Max. metering stroke
mm
184
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
12.6
Hopper capacity
Ltr.
70
8.3
General Data
11.7
125/475 – 440
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
30 / 38***
34 / 42***
35 / 43***
1,85s–332mm / 1,85s–332mm
Net weight (without oil)
kg
6600
Machine dimensions L x W x H
m
4.9* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
13.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-3
1
Technical Data
Data Sheet Demag modular 125/475 – continued Injection unit
610
Screw cylinder Screw diameter
mm
L / D – Ratio
40
45
50
20
20
20
Injection pressure (at 400 C)
bar
2418
1973
1598
Cylinder head volume
cm3
255
323
399
g
230
290
360
Shot weight in (PS) Max. metering stroke
mm
203
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
18.6
Hopper capacity
Ltr.
70
11.7
General Data
13.0
14.8
125/475 – 610
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
34 / 42***
35 / 43***
37 / 45***
1,85s–332mm / 1,85s–332mm
Net weight (without oil)
kg
6600
Machine dimensions L x W x H
m
4.9* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-4
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.2
1
Data Sheet Demag modular 150/475
Model description
Demag modular 150/475 – 320 Demag modular 150/475 – 440 Demag modular 150/475 – 610
International size code
1500 – 320 1500 – 440 1500 – 610
Clamping unit
1500
Clamping force
kN
1500
Locking force
kN
1650
Max. mould opening stroke
mm
450
Min. mould mounting height
mm
230
Max. mould mounting height
mm
460 (560
with WA)
Max. daylight between platens
mm
910 (1010
with WA)
Overall size of platens
hxv
mm
690 x 660
Daylight distance between tie bars
hxv
mm
475 x 450
Max mould weight
kg
1100
Max weight content on moving platen
kg
730
Ejection stroke
mm
140
Ejection force
kN
59
Ejector retraction force
kN
29
Hydraulic Ejector
BA027.01.1.en
1-5
1
Technical Data
Data Sheet Demag modular 150/475 – continued Injection unit
320
Screw cylinder Screw diameter
mm
L / D – Ratio
30
35
40
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
124
168
220
g
110
150
200
Shot weight in (PS) Max. metering stroke
mm
175
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
12.6
Hopper capacity
Ltr.
70
7.9
General Data
8.3
11.7
150/475 – 320
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
30 / 38***
30 / 38***
3 4 / 42***
2,05s–332mm / 2,05s–332mm
Net weight (without oil)
kg
6500
Machine dimensions L x W x H
m
4.9* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 150/475 – continued Injection unit
440
Screw cylinder Screw diameter
mm
L / D – Ratio
35
40
45
20
20
20
Injection pressure (at 400 C)
bar
2423
1855
1466
Cylinder head volume
cm3
177
231
293
g
160
210
260
Shot weight in (PS) Max. metering stroke
mm
184
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
12.6
Hopper capacity
Ltr.
70
8.3
General Data
11.7
150/475 – 440
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
30 / 38***
34 / 42***
35 / 43***
2,05s–332mm / 2,05s–332mm
Net weight (without oil)
kg
6800
Machine dimensions L x W x H
m
4.9* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
13.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-7
1
Technical Data
Data Sheet Demag modular 150/475 – continued Injection unit
610
Screw cylinder Screw diameter
mm
L / D – Ratio
40
45
50
20
20
20
Injection pressure (at 400 C)
bar
2418
1973
1598
Cylinder head volume
cm3
255
323
399
g
230
290
360
Shot weight in (PS) Max. metering stroke
mm
203
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
18.6
Hopper capacity
Ltr.
70
11.7
General Data
13.0
14.8
150/475 – 610
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
34 / 42***
35 / 43***
37 / 45***
2,05s–332mm / 2,05s–332mm
Net weight (without oil)
kg
6800
Machine dimensions L x W x H
m
4.9* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-8
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.3
1
Data Sheet Demag modular 150/500
Model description
Demag modular 150/500 – 440 Demag modular 150/500 – 610 Demag modular 150/500 – 840
International size code
1500 – 440 1500 – 610 1500 – 840
Clamping unit
1500
Clamping force
kN
1500
Locking force
kN
1650
Max. mould opening stroke
mm
500
Min. mould mounting height
mm
250
Max. mould mounting height
mm
560 (660
with WA)
Max. daylight between platens
mm
1060 (1160
with WA)
Overall size of platens
hxv
mm
750 x 750
Daylight distance between tie bars
hxv
mm
500 x 500
Max mould weight
kg
1700
Max weight content on moving platen
kg
1150
Ejection stroke
mm
160
Ejection force
kN
59
Ejector retraction force
kN
29
Hydraulic Ejector
BA027.01.1.en
1-9
1
Technical Data
Data Sheet Demag modular 150/500 – continued Injection unit
440
Screw cylinder Screw diameter
mm
L / D – Ratio
35
40
45
20
20
20
Injection pressure (at 400 C)
bar
2423
1855
1466
Cylinder head volume
cm3
177
231
293
g
160
210
260
Shot weight in (PS) Max. metering stroke
mm
184
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
12.6
Hopper capacity
Ltr.
70
8.3
General Data
11.7
13.0
150/500 – 440
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
30 / 38***
34 / 42***
35 / 43***
2,15s–350mm / 2,15s–350mm
Net weight (without oil)
kg
7500
Machine dimensions L x W x H
m
5.2* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-10
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 150/500 – continued Injection unit
610
Screw cylinder Screw diameter
mm
L / D – Ratio
40
45
50
20
20
20
Injection pressure (at 400 C)
bar
2418
1973
1598
Cylinder head volume
cm3
255
323
399
g
230
290
360
Shot weight in (PS) Max. metering stroke
mm
203
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
18.6
Hopper capacity
Ltr.
70
11.7
General Data
13.0
150/500 – 610
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
34 / 42***
35 / 43***
37 / 45***
2,15s–350mm / 2,15s–350mm
Net weight (without oil)
kg
7500
Machine dimensions L x W x H
m
5.2* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
14.8
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-11
1
Technical Data
Data Sheet Demag modular 150/500 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
23.1
150/500 – 840
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
35 / 43***
37 / 45***
45 / 53***
2,15s–350mm / 2,15s–350mm
Net weight (without oil)
kg
7800
Machine dimensions L x W x H
m
5.2* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-12
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.4
1
Data Sheet Demag modular 200/500
Model description
Demag modular 200/500 – 440 Demag modular 200/500 – 610 Demag modular 200/500 – 840
International size code
2000 – 440 2000 – 610 2000 – 840
Clamping unit
2000
Clamping force
kN
2000
Locking force
kN
2200
Max. mould opening stroke
mm
500
Min. mould mounting height
mm
250
Max. mould mounting height
mm
560 (660
with WA)
Max. daylight between platens
mm
1060 (1160
with WA)
Overall size of platens
hxv
mm
750 x 750
Daylight distance between tie bars
hxv
mm
500 x 500
Max mould weight
kg
1700
Max weight content on moving platen
kg
1150
Ejection stroke
mm
160
Ejection force
kN
59
Ejector retraction force
kN
29
Hydraulic Ejector
BA027.01.1.en
1-13
1
Technical Data
Data Sheet Demag modular 200/500 – continued Injection unit
440
Screw cylinder Screw diameter
mm
L / D – Ratio
35
40
45
20
20
20
Injection pressure (at 400 C)
bar
2423
1855
1466
Cylinder head volume
cm3
177
231
293
g
160
210
260
Shot weight in (PS) Max. metering stroke
mm
184
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
12.6
Hopper capacity
Ltr.
70
8.3
General Data
11.7
13.0
200/500 – 440
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
30 / 38***
34 / 42***
35 / 43***
2,20s–350mm / 2,20s–350mm
Net weight (without oil)
kg
7700
Machine dimensions L x W x H
m
5.2* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-14
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 200/500 – continued Injection unit
610
Screw cylinder Screw diameter
mm
L / D – Ratio
40
45
50
20
20
20
Injection pressure (at 400 C)
bar
2418
1973
1598
Cylinder head volume
cm3
255
323
399
g
230
290
360
Shot weight in (PS) Max. metering stroke
mm
203
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
18.6
Hopper capacity
Ltr.
70
11.7
General Data
13.0
200/500 – 610
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
34 / 42***
35 / 43***
37 / 45***
2,20s–350mm / 2,20s–350mm
Net weight (without oil)
kg
7700
Machine dimensions L x W x H
m
5.2* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
14.8
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-15
1
Technical Data
Data Sheet Demag modular 200/500 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
350
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
23.1
200/500 – 840
Oil tank capacity
Ltr.
400
Pump unit
kW
22 / 30
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
35 / 43***
37 / 45***
45 / 53***
2,20s–350mm / 2,20s–350mm
Net weight (without oil)
kg
8000
Machine dimensions L x W x H
m
5.2* x 1.6 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-16
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.5
1
Data Sheet Demag modular 200/560
Model description
Demag modular 200/560 – 610 Demag modular 200/560 – 840 Demag modular 200/560 – 1450
International size code
2000 – 610 2000 – 840 2000 – 1450
Clamping unit
2000
Clamping force
kN
2000
Locking force
kN
2200
Max. mould opening stroke
mm
575
Min. mould mounting height
mm
310
Max. mould mounting height
mm
660 (760
with WA)
Max. daylight between platens
mm
1235 (1335
with WA)
Overall size of platens
hxv
mm
830 x 830
Daylight distance between tie bars
hxv
mm
560 x 560
Max mould weight
kg
2500
Max weight content on moving platen
kg
1700
Ejection stroke
mm
180
Ejection force
kN
69
Ejector retraction force
kN
31
Hydraulic Ejector
BA027.01.1.en
1-17
1
Technical Data
Data Sheet Demag modular 200/560 – continued Injection unit
610
Screw cylinder Screw diameter
mm
L / D – Ratio
40
45
50
20
20
20
Injection pressure (at 400 C)
bar
2418
1973
1598
Cylinder head volume
cm3
255
323
399
g
230
290
360
Shot weight in (PS) Max. metering stroke
mm
203
Max. dist. of nozzle retraction
mm
400
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
18.6
Hopper capacity
Ltr.
70
11.7
General Data
13.0
14.8
200/560 – 610
Oil tank capacity
Ltr.
500
Pump unit
kW
30 / 37
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
42 / 49***
43 / 50***
45 / 52***
2,35s–392mm / 2,20s–392mm
Net weight (without oil)
kg
9800
Machine dimensions L x W x H
m
5.7* x 1.7 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-18
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 200/560 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
400
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
200/560 – 840
Oil tank capacity
Ltr.
500
Pump unit
kW
30 / 37
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
43 / 50***
45 / 52***
53 / 60***
2,35s–392mm / 2,20s–392mm
Net weight (without oil)
kg
10100
Machine dimensions L x W x H
m
5.7 * x 1.7 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
23.1
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-19
1
Technical Data
Data Sheet Demag modular 200/560 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
400
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
27.0
200/560 –1450
Oil tank capacity
Ltr.
500
Pump unit
kW
30 / 37
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
45 / 52***
53 / 60***
57 / 64***
2,35s–392mm / 2,20s–392mm
Net weight (without oil)
kg
10600
Machine dimensions L x W x H
m
5.7* x 1.7 x 2.2
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-20
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.6
1
Data Sheet Demag modular 250/560
Model description
Demag modular 250/560 – 610 Demag modular 250/560 – 840 Demag modular 250/560 – 1450
International size code
2500 – 610 2500 – 840 2500 – 1450
Clamping unit
2500
Clamping force
kN
2500
Locking force
kN
2750
Max. mould opening stroke
mm
575
Min. mould mounting height
mm
310
Max. mould mounting height
mm
660 (760
with WA)
Max. daylight between platens
mm
1235 (1335
with WA)
Overall size of platens
hxv
mm
830 x 830
Daylight distance between tie bars
hxv
mm
560 x 560
Max mould weight
kg
2500
Max weight content on moving platen
kg
1700
Ejection stroke
mm
180
Ejection force
kN
69
Ejector retraction force
kN
31
Hydraulic Ejector
BA027.01.1.en
1-21
1
Technical Data
Data Sheet Demag modular 250/560 – continued Injection unit
610
Screw cylinder Screw diameter
mm
L / D – Ratio
40
45
50
20
20
20
Injection pressure (at 400 C)
bar
2418
1973
1598
Cylinder head volume
cm3
255
323
399
g
230
290
360
Shot weight in (PS) Max. metering stroke
mm
203
Max. dist. of nozzle retraction
mm
400
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
18.6
Hopper capacity
Ltr.
70
11.7
General Data
13.0
14.8
250/560 –610
Oil tank capacity
Ltr.
500
Pump unit
kW
30 / 37
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
42 / 49***
43 / 50***
45 / 52***
2,35s–392mm / 2,25s–392mm
Net weight (without oil)
kg
10400
Machine dimensions L x W x H
m
5.7* x 1.7 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-22
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 250/560 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
400
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
250/560 –840
Oil tank capacity
Ltr.
500
Pump unit
kW
30 / 37
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
43 / 50***
45 / 52***
53 / 60***
2,35s–392mm / 2,25s–392mm
Net weight (without oil)
kg
10700
Machine dimensions L x W x H
m
5.7 * x 1.7 x 2.1
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
23.1
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-23
1
Technical Data
Data Sheet Demag modular 250/560 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
400
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
27.0
250/560 –1450
Oil tank capacity
Ltr.
500
Pump unit
kW
30 / 37
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
45 / 52***
53 / 60***
5 7 / 64***
2,35s–392mm / 2,25s–392mm
Net weight (without oil)
kg
11200
Machine dimensions L x W x H
m
5.7* x 1.7 x 2.2
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-24
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.7
1
Data Sheet Demag modular 250/630
Model description
Demag modular 250/630 – 840 Demag modular 250/630 – 1450 Demag modular 250/630 – 2300
International size code
2500 – 840 2500 – 1450 2500 – 2300
Clamping unit
2500
Clamping force
kN
2500
Locking force
kN
2750
Max. mould opening stroke
mm
675
Min. mould mounting height
mm
330
Max. mould mounting height
mm
710 (830
with WA)
Max. daylight between platens
mm
1385 (1505
with WA)
Overall size of platens
hxv
mm
950 x 950
Daylight distance between tie bars
hxv
mm
630 x 630
Max mould weight
kg
3300
Max weight content on moving platen
kg
2200
Ejection stroke
mm
200
Ejection force
kN
69
Ejector retraction force
kN
31
Hydraulic Ejector
BA027.01.1.en
1-25
1
Technical Data
Data Sheet Demag modular 250/630 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
440
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
23.1
250/630 –840
Oil tank capacity
Ltr.
700
Pump unit
kW
37 / 45
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
50 / 58***
52 / 60***
60 / 68***
2,70s–441mm / 2,30s–441mm
Net weight (without oil)
kg
12600
Machine dimensions L x W x H
m
6.5* x 1.9 x 2.2
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-26
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 250/630 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
440
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
250/630 –1450
Oil tank capacity
Ltr.
700
Pump unit
kW
37 / 45
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
52 / 60***
60 / 68***
64 / 72***
2,70s–441mm / 2,30s–441mm
Net weight (without oil)
kg
13100
Machine dimensions L x W x H
m
6.5* x 1.9 x 2.3
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
27.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-27
1
Technical Data
Data Sheet Demag modular 250/630 – continued Injection unit
2300
Screw cylinder Screw diameter
mm
L / D – Ratio
60
70
80
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
891
1212
1583
g
800
1090
1430
Shot weight in (PS) Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
440
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
36
Hopper capacity
Ltr.
110
23.1
General Data
27.0
30.6
250/630 –2300
Oil tank capacity
Ltr.
700
Pump unit
kW
37 / 45
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
60 / 68***
64 / 72***
68 / 76***
2,70s–441mm / 2,30s–441mm
Net weight (without oil)
kg
13800
Machine dimensions L x W x H
m
6.5* x 1.9 x 2.3
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-28
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.8
1
Data Sheet Demag modular 300/630
Model description
Demag modular 300/630 – 840 Demag modular 300/630 – 1450 Demag modular 300/630 – 2300
International size code
3000 – 840 3000 – 1450 3000 – 2300
Clamping unit
3000
Clamping force
kN
3000
Locking force
kN
3300
Max. mould opening stroke
mm
675
Min. mould mounting height
mm
330
Max. mould mounting height
mm
710 (830
with WA)
Max. daylight between platens
mm
1385 (1505
with WA)
Overall size of platens
hxv
mm
950 x 950
Daylight distance between tie bars
hxv
mm
630 x 630
Max mould weight
kg
3300
Max weight content on moving platen
kg
2200
Ejection stroke
mm
200
Ejection force
kN
69
Ejector retraction force
kN
31
Hydraulic Ejector
BA027.01.1.en
1-29
1
Technical Data
Data Sheet Demag modular 300/630 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
440
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
23.1
300/630 –840
Oil tank capacity
Ltr.
700
Pump unit
kW
37 / 45
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
50 / 58***
52 / 60***
60 / 68***
2,70s–441mm / 2,60s–441mm
Net weight (without oil)
kg
13400
Machine dimensions L x W x H
m
6.5* x 1.9 x 2.2
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-30
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 300/630 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
440
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
300/630 –1450
Oil tank capacity
Ltr.
700
Pump unit
kW
37 / 45
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
52 / 60***
60 / 68***
64 / 72***
2,70s–441mm / 2,60s–441mm
Net weight (without oil)
kg
13900
Machine dimensions L x W x H
m
6.5* x 1.9 x 2.3
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
27.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-31
1
Technical Data
Data Sheet Demag modular 300/630 – continued Injection unit
2300
Screw cylinder Screw diameter
mm
L / D – Ratio
60
70
80
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
891
1212
1583
g
800
1090
1430
Shot weight in (PS) Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
440
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
36
Hopper capacity
Ltr.
110
23.1
General Data
27.0
30.6
300/630 –2300
Oil tank capacity
Ltr.
700
Pump unit
kW
37 / 45
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
60 / 68***
64 / 72***
68 / 76***
2,70s–441mm / 2,60s–441mm
Net weight (without oil)
kg
14600
Machine dimensions L x W x H
m
6.5* x 1.9 x 2.3
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-32
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.9
1
Data Sheet Demag modular 350/710
Model description
Demag modular 350/710 – 840 Demag modular 350/710 – 1450 Demag modular 350/710 – 2300
International size code
3500 – 840 3500 – 1450 3500 – 2300
Clamping unit
3500
Clamping force
kN
3500
Locking force
kN
3850
Max. mould opening stroke
mm
675
Min. mould mounting height
mm
330
Max. mould mounting height
mm
710 (830
with WA)
Max. daylight between platens
mm
1385 (1505
with WA)
Overall size of platens
hxv
mm
1040 x 950
Daylight distance between tie bars
hxv
mm
710 x 630
Max mould weight
kg
3600
Max weight content on moving platen
kg
2400
Ejection stroke
mm
200
Ejection force
kN
69
Ejector retraction force
kN
31
Hydraulic Ejector
BA027.01.1.en
1-33
1
Technical Data
Data Sheet Demag modular 350/710 – continued Injection unit
840
Screw cylinder Screw diameter
mm
L / D – Ratio
45
50
60
20
20
20
Injection pressure (at 400 C)
bar
2402
1946
1351
Cylinder head volume
cm3
358
442
636
g
320
400
570
Shot weight in (PS) Max. metering stroke
mm
225
Max. dist. of nozzle retraction
mm
470
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
80
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
20.5
Hopper capacity
Ltr.
70
13.0
General Data
14.8
23.1
350/710 –840
Oil tank capacity
Ltr.
700
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
58 / 68***
60 / 70***
68 / 78***
2,80s–497mm / 2,70s–497mm
Net weight (without oil)
kg
14800
Machine dimensions L x W x H
m
6.5* x 2.0 x 2.2
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-34
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 350/710 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
470
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
350/710 –1450
Oil tank capacity
Ltr.
700
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
60 / 70***
68 / 78***
72 / 82***
2,80s–497mm / 2,70s–497mm
Net weight (without oil)
kg
15300
Machine dimensions L x W x H
m
6.5* x 2.0 x 2.3
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
27.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-35
1
Technical Data
Data Sheet Demag modular 350/710 – continued Injection unit
2300
Screw cylinder Screw diameter
mm
L / D – Ratio
60
70
80
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
891
1212
1583
g
800
1090
1430
Shot weight in (PS) Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
470
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
36
Hopper capacity
Ltr.
110
23.1
General Data
27.0
30.6
350/710 –2300
Oil tank capacity
Ltr.
700
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
68 / 78***
72 / 82***
7 6 / 86***
2,80s–497mm / 2,70s–497mm
Net weight (without oil)
kg
16000
Machine dimensions L x W x H
m
6.5* x 2.0 x 2.3
Contiuous sound pressure level
dB (A)
74**
*) **) ***)
1-36
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.10
1
Data Sheet Demag modular 350/810
Model description
Demag modular 350/810 – 1450 Demag modular 350/810 – 2300 Demag modular 350/810 – 3300
International size code
3500 – 1450 3500 – 2300 3500 – 3300
Clamping unit
3500
Clamping force
kN
3500
Locking force
kN
3850
Max. mould opening stroke
mm
710
Min. mould mounting height
mm
380
Max. mould mounting height
mm
820 (940
with WA)
Max. daylight between platens
mm
1530 (1650
with WA)
Overall size of platens
hxv
mm
1200 x 1100
Daylight distance between tie bars
hxv
mm
810 x 710
Max mould weight
kg
5100
Max weight content on moving platen
kg
3400
Ejection stroke
mm
230
Ejection force
kN
96
Ejector retraction force
kN
41
Hydraulic Ejector
BA027.01.1.en
1-37
1
Technical Data
Data Sheet Demag modular 350/810 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
27.0
350/810 –1450
Oil tank capacity
Ltr.
730
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
60 / 70***
68 / 78***
72 / 82***
3,20s–567mm / 3,10s–567mm
Net weight (without oil)
kg
19700
Machine dimensions L x W x H
m
7,8* x 2,2 x 2,4
Contiuous sound pressure level
dB (A)
**
*) **) ***)
1-38
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 350/810 – continued Injection unit
2300
Screw cylinder Screw diameter
mm
L / D – Ratio
60
70
80
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
891
1212
1583
g
800
1090
1430
Shot weight in (PS) Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
36
Hopper capacity
Ltr.
110
23.1
General Data
27.0
350/810 –2300
Oil tank capacity
Ltr.
730
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
68 / 78***
72 / 82***
7 6 / 86***
3,20s–567mm / 3,10s–567mm
Net weight (without oil)
kg
20000
Machine dimensions L x W x H
m
7,8* x 2,2 x 2,4
Contiuous sound pressure level
dB (A)
**
*) **) ***)
30.6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-39
1
Technical Data
Data Sheet Demag modular 350/810 – continued Injection unit
3300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
70
80
95
23
20
20
Injection pressure (at 400 C)
bar
2423
1855
1316
Cylinder head volume
cm3
1362
1779
2509
Shot weight in (PS)
g
1230
1600
2260
Shot weight in (PE)
g
–
–
–
Max. metering stroke
mm
354
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
40
Hopper capacity
Ltr.
110
30.6
General Data
30.6
42.6
350/810 – 3300
Oil tank capacity
Ltr.
730
Pump unit
kW
55 / 75
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
86 / 106 ***
86 / 106 ***
98 / 118 ***
3,10s–567mm / 3,10s–567mm
Net weight (without oil)
kg
21000
Machine dimensions L x W x H
m
7,8* x 2,2 x 2,4
Contiuous sound pressure level
dB (A)
**
*) **) ***)
1-40
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.11
1
Data Sheet Demag modular 420/800
Model description
Demag modular 420/800 – 1450 Demag modular 420/800 – 2300 Demag modular 420/800 – 3300
International size code
4200 – 1450 4200 – 2300 4200 – 3300
Clamping unit
4200
Clamping force
kN
4200
Locking force
kN
4620
Max. mould opening stroke
mm
710
Min. mould mounting height
mm
380
Max. mould mounting height
mm
820
Max. daylight between platens
mm
1530
Overall size of platens
hxv
mm
1200 x 1100
Daylight distance between tie bars
hxv
mm
800 x 710
Max mould weight
kg
5100
Max weight content on moving platen
kg
3400
Ejection stroke
mm
230
Ejection force
kN
91
Ejector retraction force
kN
45
Hydraulic Ejector
BA027.01.1.en
1-41
1
Technical Data
Data Sheet Demag modular 420/800 – continued Injection unit
1450
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
50
60
70
60
20
20
20
25
Injection pressure (at 400 C)
bar
2426
1905
1400
1905
Cylinder head volume
cm3
530
763
1039
763
Shot weight in (PS)
g
480
690
950
–
Shot weight in (PE)
g
–
–
–
560
Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
40 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
38
Hopper capacity
Ltr.
110
14.8
for SPI )
23.1
General Data Ltr.
760
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
60 / 70 ***
68 / 78 ***
72 / 82 ***
73 / 83 ***
3,20s–560mm / 2,70s–560mm
Net weight (without oil) Clamping unit / Injection Unit
kg
13600 / 4100
Machine dimensions L x W x H
m
7.9* x 2.2 x 2.5
Contiuous sound pressure level
dB (A)
70**
1-42
27.9
420/800 – 1450
Oil tank capacity
*) **) ***)
27.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 420/800 – continued Injection unit
2300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
60
70
80
70
20
20
20
25
Injection pressure (at 400 C)
bar
2420
1877
1437
1877
Cylinder head volume
cm3
891
1212
1583
1212
Shot weight in (PS)
g
810
1100
1440
–
Shot weight in (PE)
g
–
–
–
880
Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
40 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
47
Hopper capacity
Ltr.
110
23.1
for SPI )
27.0
General Data
32.2
76 / 86 ***
77 / 87 ***
420/800 – 2300
Oil tank capacity
Ltr.
760
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
68 / 78 ***
72 / 82 ***
3,20s–560mm / 2,70s–560mm
Net weight (without oil) Clamping unit / Injection Unit
kg
13600 / 4400
Machine dimensions L x W x H
m
7.9* x 2.2 x 2.5
Contiuous sound pressure level
dB (A)
70**
*) **) ***)
30.6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-43
1
Technical Data
Data Sheet Demag modular 420/800 – continued Injection unit
3300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
70
80
95
80
23
20
20
24
Injection pressure (at 400 C)
bar
2423
1855
1316
1855
Cylinder head volume
cm3
1362
1779
2509
1779
Shot weight in (PS)
g
1240
1620
2280
–
Shot weight in (PE)
g
–
–
–
1300
Max. metering stroke
mm
354
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
40 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
53
Hopper capacity
Ltr.
110
30.6
for SPI )
30.6
General Data Ltr.
760
Pump unit
kW
55 / 75
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
86 / 106 ***
86 / 106 ***
98 / 118 ***
98 / 118 ***
2,70s–560mm / 2,50s–560mm
Net weight (without oil) Clamping unit / Injection Unit
kg
13600 / 5400
Machine dimensions L x W x H
m
8.4* x 2.2 x 2.5
Contiuous sound pressure level
dB (A)
70**
1-44
43.0
420/800 – 3300
Oil tank capacity
*) **) ***)
42.6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.12
1
Data Sheet Demag modular 420/810
Model description
Demag modular 420/810 – 1450 Demag modular 420/810 – 2300 Demag modular 420/810 – 3300
International size code
4200 – 1450 4200 – 2300 4200 – 3300
Clamping unit
4200
Clamping force
kN
4200
Locking force
kN
4620
Max. mould opening stroke
mm
710
Min. mould mounting height
mm
380
Max. mould mounting height
mm
820 (940
with WA)
Max. daylight between platens
mm
1530 (1650
with WA)
Overall size of platens
hxv
mm
1200 x 1100
Daylight distance between tie bars
hxv
mm
810 x 710
Max mould weight
kg
5100
Max weight content on moving platen
kg
3400
Ejection stroke
mm
230
Ejection force
kN
96
Ejector retraction force
kN
41
Hydraulic Ejector
BA027.01.1.en
1-45
1
Technical Data
Data Sheet Demag modular 420/810 – continued Injection unit
1450
Screw cylinder Screw diameter
mm
L / D – Ratio
50
60
70
20
20
20
Injection pressure (at 400 C)
bar
2426
1905
1400
Cylinder head volume
cm3
530
763
1039
g
480
690
940
Shot weight in (PS) Max. metering stroke
mm
270
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
30
Hopper capacity
Ltr.
110
14.8
General Data
23.1
27.0
420/810 –1450
Oil tank capacity
Ltr.
730
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
60 / 70***
68 / 78***
72 / 82***
3,40s–567mm / 3,20s–567mm
Net weight (without oil)
kg
19700
Machine dimensions L x W x H
m
7,8* x 2,2 x 2,4
Contiuous sound pressure level
dB (A)
**
**) ***)
1-46
Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1
Data Sheet Demag modular 420/810 – continued Injection unit
2300
Screw cylinder Screw diameter
mm
L / D – Ratio
60
70
80
20
20
20
Injection pressure (at 400 C)
bar
2420
1877
1437
Cylinder head volume
cm3
891
1212
1583
g
800
1090
1430
Shot weight in (PS) Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
36
Hopper capacity
Ltr.
110
23.1
General Data
27.0
420/810 –2300
Oil tank capacity
Ltr.
730
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
68 / 78***
72 / 82***
76 / 86***
3,40s–567mm / 3,20s–567mm concept: 3,20s–560mm / 2,70s–560mm
Net weight (without oil)
kg
20000
Machine dimensions L x W x H
m
7,8* x 2,2 x 2,4
Contiuous sound pressure level
dB (A)
**
*) **) ***)
30.6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-47
1
Technical Data
Data Sheet Demag modular 420/810 – continued Injection unit
3300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
70
80
95
23
20
20
Injection pressure (at 400 C)
bar
2423
1855
1316
Cylinder head volume
cm3
1362
1779
2509
Shot weight in (PS)
g
1230
1600
2260
Shot weight in (PE)
g
–
–
–
Max. metering stroke
mm
354
Max. dist. of nozzle retraction
mm
620
Nozzle dipping depth (SVO)
mm
20
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
40
Hopper capacity
Ltr.
110
30.6
General Data
30.6
42.6
420/810 – 3300
Oil tank capacity
Ltr.
730
Pump unit
kW
55 / 75
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
86 / 106 ***
86 / 106 ***
98 / 118 ***
3,20s–567mm / 3,20s–567mm
Net weight (without oil)
kg
21000
Machine dimensions L x W x H
m
7,8* x 2,2 x 2,4
Contiuous sound pressure level
dB (A)
**
*) **) ***)
1-48
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.13
1
Data Sheet Demag modular 500/900
Model description
Demag modular 500/900 – 2300 Demag modular 500/900 – 3300 Demag modular 500/900 – 6400
International size code
5000 – 2300 5000 – 3300 5000 –6400
Clamping unit
5000
Clamping force
kN
5000
Locking force
kN
5500
Max. mould opening stroke
mm
810
Min. mould mounting height
mm
400
Max. mould mounting height
mm
880
Max. daylight between platens
mm
1690
Overall size of platens
hxv
mm
1300 x 1200
Daylight distance between tie bars
hxv
mm
900 x 800
Max mould weight
kg
6700
Max weight content on moving platen
kg
4400
Ejection stroke
mm
230
Ejection force
kN
91
Ejector retraction force
kN
45
Hydraulic Ejector
BA027.01.1.en
1-49
1
Technical Data
Data Sheet Demag modular 500/900 – continued Injection unit
2300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
60
70
80
70
20
20
20
25
Injection pressure (at 400 C)
bar
2420
1877
1437
1877
Cylinder head volume
cm3
891
1212
1583
1212
Shot weight in (PS)
g
810
1100
1440
–
Shot weight in (PE)
g
–
–
–
880
Max. metering stroke
mm
315
Max. dist. of nozzle retraction
mm
650
Nozzle dipping depth (SVO)
mm
40 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
47
Hopper capacity
Ltr.
110
23.1
for SPI )
27.0
General Data Ltr.
760
Pump unit
kW
45 / 55
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
68 / 78 ***
72 / 82 ***
76 / 86 ***
77 / 87 ***
3,80s–630mm / 3,60s–630mm
Net weight (without oil) Clamping unit / Injection Unit
kg
16500 / 4400
Machine dimensions L x W x H
m
8.2* x 2.3 x 2.5
Contiuous sound pressure level
dB (A)
70**
1-50
32.2
500/900 – 2300
Oil tank capacity
*) **) ***)
30.6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 500/900 – continued Injection unit
3300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
70
80
95
80
23
20
20
24
Injection pressure (at 400 C)
bar
2423
1855
1316
1855
Cylinder head volume
cm3
1362
1779
2509
1779
Shot weight in (PS)
g
1240
1620
2280
–
Shot weight in (PE)
g
–
–
–
1300
Max. metering stroke
mm
354
Max. dist. of nozzle retraction
mm
650
Nozzle dipping depth (SVO)
mm
40 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
53
Hopper capacity
Ltr.
110
30.6
for SPI )
30.6
General Data
43.0
98 / 118 ***
98 / 118 ***
500/900 – 3300
Oil tank capacity
Ltr.
760
Pump unit
kW
55 / 75
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
86 / 106 ***
86 / 106 ***
3,60s–630mm / 3,40s–630mm
Net weight (without oil) Clamping unit / Injection Unit
kg
16500 / 5400
Machine dimensions L x W x H
m
8.7* x 2.3 x 2.5
Contiuous sound pressure level
dB (A)
70**
*) **) ***)
42.6
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-51
1
Technical Data
Data Sheet Demag modular 500/900 – continued Injection unit
6400
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
80
95
110
95
24
20
20
23
Injection pressure (at 400 C)
bar
2391
1895
1413
1895
Cylinder head volume
cm3
2388
3367
4514
3367
Shot weight in (PS)
g
2170
3060
4110
–
Shot weight in (PE)
g
–
–
–
2460
Max. metering stroke
mm
475
Max. dist. of nozzle retraction
mm
650
Nozzle dipping depth (SVO)
mm
45 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
90
Hopper capacity
Ltr.
110
General Data
42.6
for SPI )
42.6
59.0
500/900 – 6400
Oil tank capacity
Ltr.
1300
Pump unit
kW
75 / 90
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
118 / 133 ***
118 / 133 ***
134 / 149 134 / 149 *** ***
3,40s–630mm / 3,30s–630mm
Net weight (without oil) Clamping unit / Injection Unit
kg
16500 /7800
Machine dimensions L x W x H
m
10.3* x 2.3 x 2.5
Contiuous sound pressure level
dB (A)
70**
*) **) ***)
1-52
59.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.14
1
Data Sheet Demag modular 650/1000
Model description
Demag modular 650/1000 – 3300 Demag modular 650/1000 – 6400 Demag modular 650/1000 – 9500
International size code
6500 – 3300 6500 – 6400 6500 – 9500
Clamping unit
6500
Clamping force
kN
6500
Locking force
kN
7150
Max. mould opening stroke
mm
930
Min. mould mounting height
mm
450
Max. mould mounting height
mm
950
Max. daylight between platens
mm
1880
Overall size of platens
hxv
mm
1450 x 1350
Daylight distance between tie bars
hxv
mm
1000 x 900
Max mould weight
kg
8600
Max weight content on moving platen
kg
5700
Ejection stroke
mm
300
Ejection force
kN
139
Ejector retraction force
kN
57
Hydraulic Ejector
BA027.01.1.en
1-53
1
Technical Data
Data Sheet Demag modular 650/1000 – continued Injection unit
3300
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
70
80
95
80
23
20
20
24
Injection pressure (at 400 C)
bar
2423
1855
1316
1855
Cylinder head volume
cm3
1362
1779
2509
1779
Shot weight in (PS)
g
1240
1620
2280
–
Shot weight in (PE)
g
–
–
–
1300
Max. metering stroke
mm
354
Max. dist. of nozzle retraction
mm
720
Nozzle dipping depth (SVO)
mm
45 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
53
Hopper capacity
Ltr.
110
General Data
30.6
for SPI )
30.6
42.6
43.0
118 / 133 ***
118 / 133 ***
650/1000 – 3300
Oil tank capacity
Ltr.
760 / 1300
Pump unit
kW
75 / 90
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
106 / 121 106 / 121 *** ***
4,20s–700mm / 3,90s–700mm
Net weight (without oil) Clamping unit / Injection Unit
kg
25700 / 5400 (75 25700 / 7400 ( 90
kW ) kW )
Machine dimensions L x W x H
m
9.4* x 2.5 x 2.6 (75 10.4* x 2.5 x 2.6 (90
kW ) kW )
Contiuous sound pressure level
dB (A)
*) **) ***)
1-54
70**
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 650/1000 – continued Injection unit
6400
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
80
95
110
95
24
20
20
23
Injection pressure (at 400 C)
bar
2391
1895
1413
1895
Cylinder head volume
cm3
2388
3367
4514
3367
Shot weight in (PS)
g
2170
3060
4110
–
Shot weight in (PE)
g
–
–
–
2460
Max. metering stroke
mm
475
Max. dist. of nozzle retraction
mm
720
Nozzle dipping depth (SVO)
mm
45 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
90
Hopper capacity
Ltr.
110
General Data
42.6
for SPI )
42.6
59.0
650/1000 –6400
Oil tank capacity
Ltr.
1300
Pump unit
kW
75 / 90
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
118/133 ***
118 /133 ***
134 / 149 134 / 149 *** ***
4,20s–700mm / 3,90s–700mm
Net weight (without oil) Clamping unit / Injection Unit
kg
25700 / 7800
Machine dimensions L x W x H
m
11.0* x 2.5 x 2.6
Contiuous sound pressure level
dB (A)
70**
*) **) ***)
59.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-55
1
Technical Data
Data Sheet Demag modular 650/1000 – continued Injection unit
9500
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
95
110
130
110
23
20
20
24
Injection pressure (at 400 C)
bar
2434
1815
1300
1815
Cylinder head volume
cm3
3899
5227
7300
5227
Shot weight in (PS)
g
3550
4760
6640
–
Shot weight in (PE)
g
–
–
–
3820
Max. metering stroke
mm
550
Max. dist. of nozzle retraction
mm
720
Nozzle dipping depth (SVO)
mm
45 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
115
Hopper capacity
Ltr.
110
General Data
59.0
for SPI )
59.0
Ltr.
1300
Pump unit
kW
90 / 110
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
149 / 169 149 / 169 169 / 189 169 / 189 *** *** *** *** 3,90s–700mm / 3,50s–700mm
Net weight (without oil) Clamping unit / Injection Unit
kg
25700 / 9700
Machine dimensions L x W x H
m
11.8* x 2.5 x 2.6
Contiuous sound pressure level
dB (A)
70**
1-56
79.0
650/1000 – 9500
Oil tank capacity
*) **) ***)
79.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
Technical Data
1.1.15
1
Data Sheet Demag modular 800/1120
Model description
Demag modular 800/1120 – 6400 Demag modular 800/1120 –9500
International size code
8000 – 6400 8000 – 9500
Clamping unit
8000
Clamping force
kN
8000
Locking force
kN
8800
Max. mould opening stroke
mm
1030
Min. mould mounting height
mm
500
Max. mould mounting height
mm
1050
Max. daylight between platens
mm
2080
Overall size of platens
hxv
mm
1620 x 1500
Daylight distance between tie bars
hxv
mm
1120 x 1000
Max mould weight
kg
10800
Max weight content on moving platen
kg
7200
Ejection stroke
mm
350
Ejection force
kN
139
Ejector retraction force
kN
57
Hydraulic Ejector
BA027.01.1.en
1-57
1
Technical Data
Data Sheet Demag modular 800/1120 – continued Injection unit
6400
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
80
95
110
95
24
20
20
23
Injection pressure (at 400 C)
bar
2391
1895
1415
1895
Cylinder head volume
cm3
2388
3367
4514
3367
Shot weight in (PS)
g
2170
3060
4110
–
Shot weight in (PE)
g
–
–
–
2460
Max. metering stroke
mm
475
Max. dist. of nozzle retraction
mm
800
Nozzle dipping depth (SVO)
mm
45 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
90
Hopper capacity
Ltr.
110
General Data
42.6
for SPI )
42.6
59.0
800/1120 – 6400
Oil tank capacity
Ltr.
1300
Pump unit
kW
75 / 90
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
118/133 ***
118 /133 ***
134 / 149 134 / 149 *** ***
4,50s–784mm / 4,30s–784mm
Net weight (without oil) Clamping unit / Injection Unit
kg
33500 / 7800
Machine dimensions L x W x H
m
11.6* x 2.7 x 2.7
Contiuous sound pressure level
dB (A)
70**
*) **) ***)
1-58
59.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1
Technical Data
Data Sheet Demag modular 800/1120 – continued Injection unit
9500
Screw cylinder Screw diameter
Standard mm
L / D – Ratio
Special
95
110
130
110
23
20
20
24
Injection pressure (at 400 C)
bar
2434
1815
1300
1815
Cylinder head volume
cm3
3899
5227
7300
5227
Shot weight in (PS)
g
3550
4760
6640
–
Shot weight in (PE)
g
–
–
–
3820
Max. metering stroke
mm
550
Max. dist. of nozzle retraction
mm
860
Nozzle dipping depth (SVO)
mm
45 (30
Nozzle sealing force
kN
110
Heating capac. of screw cylind.
kW
Electrical screw drive (WA)
kW
115
Hopper capacity
Ltr.
110
General Data
59.0
for SPI )
59.0
79.0
800/1120 – 9500
Oil tank capacity
Ltr.
1300
Pump unit
kW
90 / 110
Total installed electrical rating
kW
Number of dry cycles to EUROMAP 6
149 / 169 149 / 169 169 / 189 169 / 189 *** *** *** *** 4,30s–784mm / 4,10s–784mm
Net weight (without oil) Clamping unit / Injection Unit
kg
33500 / 9700
Machine dimensions L x W x H
m
12.3* x 2.7 x 2.7
Contiuous sound pressure level
dB (A)
70**
*) **) ***)
79.0
without extension of injection unit, see chap. 2.2 Operator side measured to EN 201 – annex D, see chap. 3.1.6 Demag modular with el. screw drive the total installed electrical rating increases by the rating of the screw drive
BA027.01.1.en
1-59
1
Technical Data
1.2
Mould Mounting Dimensions
1.2.1 1.2.1.1
Mould mounting dimensions Demag modular 125/475 Mould mounting dimensions Demag modular 125/475: DIN layout 105
min. 230 max. 460 560 A B
35
20
100
450
Z
280 175
M16 X 32
125 H8
125 H8
330
Z
12
A
B
B–B 621
716
690
M16
A–A 540 475
470
140 210 280
515
450 70
65
140
210
280
660
70
40
k = smallest permissible mould 285
1-60
BA027.01.1.en
Technical Data
1.2.1.2
1
Mould mounting dimensions Demag modular 125/475: SPI layout 450
min. 230 max. 460 560
105
35
100
20
Z
330
M16 X 32 280 175
125 H8 101.6 H8
27
Z
12
B
621
716
A–A 540
88.9 50.8
475
40
450 515 76.2 127 177.8
470 254 304.8
BA027.01.1.en
65
88.9 50.8
254 177.8 127
660 139.7
76.2
690 203.2
5/8”–11.UNC
A B–B
k
k = smallest permissible mould 285
1-61
1
Technical Data
Mould mounting dimensions Demag modular 125/475: EUROMAP layout min. 230 max. 460 560 A B
105
35 Z
20 Z
125 H8 125 H8
27
330
100
450
M16 x 32 280 175
1.2.1.3
12
A
B–B
716 M16
621
B
A–A
690 203.2
475
32
70 470
140 175 210 245 280 315
1-62
65
50,8
280 245 210 175 140
450 515
70
660 139,7
50.8
540
k
k = smallest permissible mould 285
BA027.01.1.en
1
Technical Data
1.2.2 1.2.2.1
Mould mounting dimensions Demag modular 150/475 Mould mounting dimensions Demag modular 150/475: DIN layout 105
min. 230 max. 460 560 A B
35 Z
20
100
450
280 175
M16 X 32
125 H8
125 H8
330
Z
12
A
B
B–B 621
716
690
M16
A–A 545 475
470
140 210 280
520
450 70
70
140
210
280
660
70
40
k
k = smallest permissible mould 285
BA027.01.1.en
1-63
1
Technical Data
Mould mounting dimensions Demag modular 150/475: SPI layout 450
min. 230 max. 460 560
105
35 Z
M16 X 32 280 175
125 H8 101.6 H8
27
100
20 Z 330
1.2.2.2
12
621
B 716
A–A 545
88.9 50.8
475
40
450 520 76.2 127 177.8
470
k
254 304.8
1-64
70
88.9 50.8
254 177.8 127
660 139.7
76.2
690 203.2
5/8”–11.UNC
A
B–B
k = smallest permissible mould 285
BA027.01.1.en
Technical Data
Mould mounting dimensions Demag modular 150/475: EUROMAP layout min. 230 max. 460 560 A B
105
35
20 Z
Z
125 H8 125 H8
27
330
100
450
M16 x 32 280 175
1.2.2.3
1
12
A
B
B–B 716 M16
621
A–A
690 203.2
475
32
70 470
BA027.01.1.en
140 175 210 245 280 315
70
50,8
280 245 210 175 140
450 520
70
660 139,7
50.8
545
k
k = smallest permissible mould 285
1-65
Technical Data
Mould mounting dimensions Demag modular 150/500 Mould mounting dimensions Demag modular 150/500: DIN layout min. 250 max. 560 660 B A
160 H8
160 H8
100
500
105
35
20 Z
Z
M16 X 32 280 175
1.2.3 1.2.3.1
375
1
15
B–B
656
B 736
M20
A
A–A 570
750
500
140
510
210 280
k
350 k = smallest permissible mould 300
1-66
BA027.01.1.en
570
500 70
70
140
210
280
350
750
70
45
Technical Data
Mould mounting dimensions Demag modular 150/500: SPI layout min. 250 max. 560 660 A B
105
35
20 Z
Z
M16 X 32 280 175
160 H8 101.6 H8
27
100
500
375
1.2.3.2
1
15
B
A–A 570 40
500
177.8
254
76.2
50.8 88.9 203.2 510
BA027.01.1.en
330.2
50.8 88.9 139.7
750
127
750
500 570
736
76.2
656
127 177.8 254 330.2
70
B–B
5/8”–11.UNC
A
k
k = smallest permissible mould 300
1-67
1
Technical Data
Mould mounting dimensions Demag modular 150/500: EUROMAP layout min. 250 max. 560 660 B A
105
35 Z
375
20 Z
160 H8 160 H8
27
100
500
M16 x 32 280 175
1.2.3.3
15
656
B M16
A B–B
736
A–A 570 32
500
203.2 510
140 210 280 k
350
k = smallest permissible mould 300
BA027.01.1.en
570
500 70
50.8
1-68
70
140
210
280
350
50.8
750
70
139.7
750
Technical Data
1.2.4 1.2.4.1
1
Mould mounting dimensions Demag modular 200/500 Mould mounting dimensions Demag modular 200/500: DIN layout min. 250 max. 560 660 B A
105
35
20 Z
Z
M16 X 32 280 175
160 H8
160 H8
375
100
500
15
B–B
656
B 736
M20
A
A–A 580
750
500
140
510
210 280
k
350 k = smallest permissible mould 300
BA027.01.1.en
1-69
580
500 70
80
140
210
280
350
750
70
45
1
Technical Data
Mould mounting dimensions Demag modular 200/500: SPI layout min. 250 max. 560 660 A B
105
35
20 Z
Z
M16 X 32 280 175
160 H8 101.6 H8
27
100
500
375
1.2.4.2
15
B A–A 580 40
500
500 580
177.8
254
76.2
50.8 88.9 203.2 510
1-70
330.2
50.8 88.9 139.7
750
127
750
127 177.8 254 330.2
80
736
76.2
656
5/8”–11.UNC
A B–B
k
k = smallest permissible mould 300
BA027.01.1.en
Technical Data
Mould mounting dimensions Demag modular 200/500: EUROMAP layout 105
min. 250 max. 560 660 B A
375
Z
160 H8 160 H8
27
35
20 Z
100
500
M16 x 32 280 175
1.2.4.3
1
15
656
B A–A
M16
A
B–B
736
580 32
500
203.2 510
140 210 280 350 k = smallest permissible mould 300
k
1-71
580
500 70
50.8
BA027.01.1.en
80
140
210
280
350
50.8
750
70
139.7
750
1
Technical Data
1.2.5 1.2.5.1
Mould mounting dimensions Demag modular 200/560 Mould mounting dimensions Demag modular 200/560: DIN layout min. 310 max. 660 760 A B
100
575
175
35
20
Z
M20 X 40 350 210
160 H8
160 H8
415
Z
15
B
706
786
M20
A B–B
A–A 640 560
45
560 640
280 210 140
350
830
70
830
600
140 210 280
80
70
k
350 k = smallest permissible mould 350
1-72
BA027.01.1.en
Technical Data
Mould mounting dimensions Demag modular 200/560: SPI layout min. 310 max. 660 760 A B
175
35
20 Z
Z
M20 X 40
350 210
160 H8 101.6 H8
27
100
575
415
1.2.5.2
1
15
B 5/8”–11UNC
786
830
A–A
177.8
381 330.2 254
203.2
127 76.2
40
50.8 76.2 88.9 830
640 560
203.2 355.6 600
177.8 254 330.2
80
76.2 127
50.8 88.9
k
381
BA027.01.1.en
k = smallest permissible mould 350
1-73
640
706
560
A B–B
1
Technical Data
Mould mounting dimensions Demag modular 200/560: EUROMAP layout min. 310 max. 660 760 A B
175
35
20 Z
Z
M20 X 40 350 210
160 H8 160 H8
27
100
575
415
1.2.5.3
15
786
830
A–A 640 560
70 210 140
350 280
203.2
830
50.8
40
560 640
706
70
50.8 203.2 600
140 210 280 350
80
B–B
B M20
A
k
k = smallest permissible mould 350
1-74
BA027.01.1.en
Technical Data
1.2.6 1.2.6.1
1
Mould mounting dimensions Demag modular 250/560 Mould mounting dimensions Demag modular 250/560: DIN layout min. 310 max. 660 760 A B
100
575
175
35
20
Z
M20 X 40 350 210
160 H8
160 H8
415
Z
15
B
706
786
M20
A B–B
A–A 650 560
45
560 650
280 210 140
350
830
70
830
600
140 210 280
90
70
k
350 k = smallest permissible mould 350
BA027.01.1.en
1-75
Mould mounting dimensions Demag modular 250/560: SPI layout min. 310 max. 660 760 A B
175
35
20 Z
160 H8 101.6 H8
27
100
575
Z
M20 X 40 350 210
1.2.6.2
Technical Data
415
1
15 B 5/8”–11UNC
706
786
830
A–A 650 560
560
127 76.2 381 330.2 254 177.8
203.2
830
50.8 76.2 88.9
40
88.9 203.2 355.6 600
90
76.2 127
50.8 177.8 254 330.2
k
381
1-76
k = smallest permissible mould 350
BA027.01.1.en
650
A B–B
Technical Data
Mould mounting dimensions Demag modular 250/560: EUROMAP layout min. 310 max. 660 760 A B
175
35
20 Z
Z
M20 X 40 350 210
160 H8 160 H8
27
100
575
415
1.2.6.3
1
15
786
830
A–A 650 560
70 210 140
350 280
203.2
830
50.8
40
560 650
706
70
50.8 203.2 600
140 210 280 350
90
B–B
B
M20
A
k
k = smallest permissible mould 350
BA027.01.1.en
1-77
1
1.2.7 1.2.7.1
Technical Data
Mould mounting dimensions Demag modular 250/630 Mould mounting dimensions Demag modular 250/630: DIN layout min. 330 max. 710 830 A B
175
35 Z
20 Z
M20 X 40 420 280
200 H8
200 H8
475
125
675
15
B–B
766
B 846
A–A
M24
A
720 630
950
690
420
90
140 210 280 350
k
k = smallest permissible mould 400
1-78
BA027.01.1.en
720
630
210
280
350
420
950
140
50
Technical Data
Mould mounting dimensions Demag modular 250/630: SPI layout
35
20 Z
160 H8 101.6 H8
27
175
Z
M20 X 40 420 280
min. 330 max. 710 830 A B
125
675
475
1.2.7.2
1
15
B 846
766
950
A–A
720 630
630
431.8 330.2 254
950
50.8 76.2 88.9 203.2
177.8 127 76.2
40
50.8 88.9 203.2 355.6 690
254 330.2 431.8
90
76.2 127 177.8 k
BA027.01.1.en
k = smallest permissible mould 400
1-79
720
B–B
5/8”–11UNC
A
1
Technical Data
1.2.7.3
Mould mounting dimensions Demag modular 250/630: EUROMAP layout min. 330 max. 710 830 A B
175
475
Z
M20 X 40 420 280
160 H8 160 H8
27
35
20 Z
125
675
15
A–A
720 630
40
203.2
420 350 280 210
950
50.8
950
90
50.8 140 203.2 690
210 280 350 420
k
k = smallest permissible mould 400
1-80
BA027.01.1.en
720
846
140
766
630
B
M20
A B–B
Technical Data
1.2.8 1.2.8.1
1
Mould mounting dimensions Demag modular 300/630 Mould mounting dimensions Demag modular 300/630: DIN layout min. 330 max. 710 830 A B
175
35 Z
20 Z
M20 X 40 420 280
200 H8
200 H8
475
125
675
15
A
B
B–B 846
A–A
M24
766
735 630
950
690
210 280 350 420
105
140
k
k = smallest permissible mould 400
BA027.01.1.en
1-81
735
630
210
280
350
420
950
140
50
1
Technical Data
Mould mounting dimensions Demag modular 300/630: SPI layout
35
20 Z
160 H8 101.6 H8
27
175
Z
M20 X 40 420 280
min. 330 max. 710 830 A B
125
675
475
1.2.8.2
15
B
950
A–A
735 630
630
50.8 88.9 203.2
105
431.8 330.2 254
950
50.8 76.2 88.9 203.2
177.8 127 76.2
40
76.2 127 177.8 355.6 690
254 330.2 431.8
k
1-82
k = smallest permissible mould 400
BA027.01.1.en
735
846
766
5/8”–11UNC
A B–B
Technical Data
1.2.8.3
1
Mould mounting dimensions Demag modular 300/630: EUROMAP layout min. 330 max. 710 830 A B
175
475
Z
M20 X 40 420 280
160 H8 160 H8
27
35
20 Z
125
675
15
A–A
735 630
40
203.2
105
50.8 140 203.2 690
210 280 350 420
k
k = smallest permissible mould 400
BA027.01.1.en
1-83
735
420 350 280 210
950
50.8
950
630
846
140
766
B M20
A
B–B
1
1.2.9 1.2.9.1
Technical Data
Mould mounting dimensions Demag modular 350/710 Mould mounting dimensions Demag modular 350/710: DIN layout min. 330 max. 710 830 A B
175
35
20 Z
Z
M20 X 40 490 350
200 H8
200 H8
475
125
675
15
A
B
B–B A–A
M24
780
945
815 710
1040
690
210 280 350 420 490
105
140
k
k = smallest permissible mould 400
1-84
BA027.01.1.en
735
630
210
280
350
420
950
140
50
Technical Data
Mould mounting dimensions Demag modular 350/710: SPI layout min. 330 max. 710 830 B A
175
35
20 Z
Z
M20 X 40 490 350
160 H8 101.6 H8
27
125
675
475
1.2.9.2
1
15
B
B–B
780
A–A
5/8”–11UNC
A 945
1040
815 710
76.2 127 177.8 355.6 690
254 330.2 431.8 482.6
k
BA027.01.1.en
k = smallest permissible mould 400
1-85
735
630
50.8 88.9 203.2
105
431.8 330.2 254
950
50.8 76.2 88.9 203.2
177.8 127 76.2
40
Mould mounting dimensions Demag modular 350/710: EUROMAP layout min. 330 max. 710 830 A B
175
35
20 Z
Z
160 H8 160 H8
27
125
675
M20 X 40
490 350
1.2.9.3
Technical Data
475
1
15
815 710
40
203.2
105
50.8 140 203.2 690
210 280 350 420 490
k
k = smallest permissible mould 400
1-86
BA027.01.1.en
735
420 350 280 210
950
50.8
1040
630
945
A–A
140
780
B
M20
A
B–B
1
Technical Data
1.2.10 1.2.10.1
Mould mounting dimensions Demag modular 350/810 Mould mounting dimensions Demag modular 350/810: DIN layout 175
min. 380 max. 820 940 A B
35
20 Z
Z
M20 X 40 490 350
200 H8
200 H8
550
125
710
15
A
B
900
M24
B–B 1030 1200
A–A 930 810
140 850
210 280 350
k
420 490 560 k = smallest permissible mould 420
BA027.01.1.en
1-87
830
710 120
280 210
420 350
490
1100
140
50
1
Technical Data
Mould mounting dimensions Demag modular 350/810: SPI layout 175
35
20 Z
Z
160 H8 101.6 H8
27
125
min. 380 max. 820 940 B A
M20 X 40 490 350
710
550
1.2.10.2
15
B 3/4”–10UNC
930 810
76.2 88.9 203.2
45
482.6 431.8 330.2 254 177.8
127
50.8
1100
1200
A–A
50.8 88.9 203.2 355.6 508 850
177.8 254 330.2 431.8 533.4
120
76.2 127 k
1-88
k = smallest permissible mould 420
BA027.01.1.en
830
1030
127 76.2
900
710
A B–B
Technical Data
1.2.10.3
1
Mould mounting dimensions Demag modular 350/810: EUROMAP layout min. 380 max. 820 940 A B
175
550
Z
490 350
160 H8 160 H8
27
35
20 Z
125
710
M20 X 40
15
A
B M20
B–B 1030
900
A–A 930
1200
810
50.8
120
140 203.2
850
210 280 350 420 490 560
k
k = smallest permissible mould 420
BA027.01.1.en
1-89
830
490 420 350 280 210
710
140
203.2
1100
50.8
40
1
Technical Data
1.2.11 1.2.11.1
Mould mounting dimensions Demag modular 420/800 Mould mounting dimensions Demag modular 420/800: DIN layout 710
min. 380 max. 820
A
35 40 Z
Z
M20 X 40 490 350
200 H8
200 H8
550
125
B
175
15 50
900
1030
B M24
A B–B
A–A 920
1200 800
140 850
210 280 350
k
420 490 560 k = smallest permissible mould 420
1-90
BA027.01.1.en
830
710 120
280 210
490 420 350
1100
140
50
1
Technical Data
Mould mounting dimensions Demag modular 420/800 : SPI layout min. 380 max. 820 A B
175 35
30 Z
Z
M20 x 40 490 350
160 H8 101.6 H8
27
125
710
550
1.2.11.2
15
920 800
76.2 88.9 203.2
45
482.6 431.8 330.2 254 177.8
127
50.8
1100
1200
A–A
50.8 88.9 203.2 355.6 508 850
254 330.2 431.8 533.4
120
76.2 127 177.8 k
BA027.01.1.en
k = smallest permissible mould 420
1-91
830
B
1030
710
A 900
127 76.2
B–B
3/4”–10UNC
10
1
Technical Data
1.2.11.3
Mould mounting dimensions Demag modular 420/800: EUROMAP layout min. 380 max. 820 B A
175 35 40
125
710
Z
550
M20 X 40 490 350
160 H8 160 H8
27
Z
15 30 M20
B
A
B–B
1030
900
A–A 920
1200
800
50.8
120
140 203.2
850
210 280 350
k
420 490 560 k = smallest permissible mould 420
1-92
BA027.01.1.en
830
490 420 350 280 210
710
140
203.2
1100
50.8
40
1
Technical Data
1.2.12 1.2.12.1
Mould mounting dimensions Demag modular 420/810 Mould mounting dimensions Demag modular 420/810: DIN layout 175
min. 380 max. 820 940 A B
35
20 Z
Z
M20 X 40 490 350
200 H8
200 H8
550
125
710
15
900
B
M24
A
B–B
A–A 930
1030 1200
810
140
850
210 280 350
k
420 490 560 k = smallest permissible mould 420
BA027.01.1.en
1-93
830
710 120
280 210
420 350
490
1100
140
50
1
Technical Data
Mould mounting dimensions Demag modular 420/810: SPI layout min. 380 max. 820 940 B A
175
35
20 Z
Z
M20 X 40 490 350
160 H8 101.6 H8
27
125
710
550
1.2.12.2
15
B
930 810
76.2 88.9 203.2
45
482.6 431.8 330.2 254 177.8
127
50.8
1100
1200
A–A
50.8 88.9 203.2 355.6 508 850
177.8 254 330.2 431.8 533.4
120
76.2 127 k
1-94
k = smallest permissible mould 420
BA027.01.1.en
830
1030
127 76.2
900
3/4”–10UNC
B–B
710
A
Technical Data
1.2.12.3
1
Mould mounting dimensions Demag modular 420/810: EUROMAP layout min. 380 max. 820 940 A B
175
550
Z
490 350
160 H8 160 H8
27
35
20 Z
125
710
M20 X 40
15
A
B M20
B–B 1030
900
A–A 930
1200
810
50.8 203.2 850
210 280 350 420 490 560
120
140
k
k = smallest permissible mould 420
BA027.01.1.en
1-95
830
490 420 350 280 210
710
140
203.2
1100
50.8
40
1
Technical Data
Mould mounting dimensions Demag modular 500/900 Mould mounting dimensions Demag modular 500/900: DIN layout min. 400 max. 880 A B
175 35 40 Z
Z
M20 X 40 560 420
200 H8
200 H8
125
810
600
1.2.13 1.2.13.1
15 50
970
B
1095
M24
A
B–B
A–A 1025
1300 900
956
210 280 350
125
140 k
420 490 560 k = smallest permissible mould 420
1-96
BA027.01.1.en
925
800
560 490 420 350 280 210
1200
140
50
Technical Data
Mould mounting dimensions Demag modular 500/900 : SPI layout min. 400 max. 880 B A
175 35
30 Z
Z
M20 x 40 560 420
200 H8 101.6 H8
27
125
810
600
1.2.13.2
1
15 10 B
A 970
3/4”–10UNC
B–B
1095 1300
A–A 1025 900
50.8 88.9 203.2 355.6 508 956
76.2 127 177.8 254 330.2 431.8
125 k
533.4
BA027.01.1.en
k = smallest permissible mould 420
1-97
925
127
533.4 431.8 330.2 254 177.8
800
127 76.2
76.2 88.9 203.2
50.8
1200
45
1
1.2.13.3
Technical Data
Mould mounting dimensions Demag modular 500/900: EUROMAP layout 810
min. 400 max. 880 A
175 35
B Z
M20 x 40 560 420
200 H8 200 H8
600
52+1
125
40
15 50 B M20
A
B–B 1095
970
A–A 1025
1300 900
490 420 350 280
560 355.6 956
280 350 420 490 560
125
140 50.8
k
1-98
k = smallest permissible mould 420
BA027.01.1.en
925
800
1200
140
76.2 203.2
40
Technical Data
Mould mounting dimensions Demag modular 650/1000 Mould mounting dimensions Demag modular 650/1000: DIN layout min. 450 max. 950 A
280 45
175
B
Z
70 675
Z
M24 X 48 630 420
200 H8
160
930
200 H8
1.2.14 1.2.14.1
1
15 40
1045
B
A–A
M24
A
B–B
1180
1140
1450
1000
140 210
1120 280 350 420 490 560 630
k
k = smallest permissible mould 500
BA027.01.1.en
1-99
1040
900 140
490 420 350 280 210
560
630
1350
140
50
1
Technical Data
Mould mounting dimensions Demag modular 650/1000 : SPI layout min. 450 max. 950 A
175
30
70
Z
200 H8 101,6 H8
27
B
280
Z
M24 X 48 630 420
160
930
675
1.2.14.2
15 10 B
3/4”–10UNC
A B–B
1180
1045 1450
A–A
1140 1000
900 1040
76.2
50.8 76.2 88,9 203.2 355.6 508 1120
1-100
76.2 127 177.8 254 330.2 431.8 533.4 635
140
533.4 431.8 330.2 254 177.8 127
88,9 127 203.2 355.6
1350
50.8 76.2
45
k
k = smallest permissible mould 500
BA027.01.1.en
Technical Data
Mould mounting dimensions Demag modular 650/1000: EUROMAP layout min. 450 max. 950 A
280 45
175
B
70
Z
Z
M24 X 48 630 420
200 H8 200 H8
52+1
160
930
675
1.2.14.3
1
15 40
1045
B A–A
M20
A B–B
1180 1450
1140 1000
1120
BA027.01.1.en
280 350 420 490 560 630 700
140
140
76.2 355.6
k
k = smallest permissible mould 500
1-101
1040
900
140 630 560 490 420 350 280
355.6
1350
76.2
40
1
Technical Data
Mould mounting dimensions Demag modular 800/1120 Mould mounting dimensions Demag modular 800/1120: DIN layout
B
175
45
70
Z
Z
M24 X 48
700 420
A
280
750
min. 500 max. 1050
250 H8
160
1030
250 H8
1.2.15 1.2.15.1
25 70 A 1140
B
A–A
M24
B–B
1265
1280
1620
1120
210 1210
280 350 420
k
490 560 630 700 k = smallest permissible mould 600
1-102
BA027.01.1.en
1160
1000 160
630 560 490 420 350 280
700
1500
210
50
1
Technical Data
Mould mounting dimensions Demag modular 800/1120 : SPI layout min. 500 max. 1050
30
B
175
Z
250 H8 127 H8
52+1
160
A
280 Z
70
M24 X 48 700 420
1030
750
1.2.15.2
25 10 A
B
1140
A–A
1”–8UNC
B–B 1265 1620
1280 1120
177.8 76.2 355.6 508 660.4 1210
BA027.01.1.en
160
50.8 254 330.2 431.8 533.4 635 736.6
k
k = smallest permissible mould 600
1-103
1160
1000
177.8 635 533.4 431.8 330.2 254
355.6
127 203.2
1500
76.2
50
Mould mounting dimensions Demag modular 800/1120: EUROMAP layout 1030
min. 500 max. 1050 A
280 175
B
250 H8 250 H8
52+1
160
Z
70
45 Z
M24 X 48 700 420
1.2.15.3
Technical Data
750
1
25 70
B–B 1140
B A–A
M24
A 1265
1280
1620
1120
76.2 355.6 1210
160
140 280 420 560
k
700
1-104
k = smallest permissible mould 600
BA027.01.1.en
1160
700 560 420 280
1000
140
355.6
1500
76.2
48
Table of contents
2
2
Commissioning and Dismantling 2.1
Cable Suspension Diagrams and machine weights . . . . . . . . . . . . . . . . . . . . .
2-1
2.1.1
Cable Suspension Diagram and machine weights – Demag modular 125/475 up to 350/810 and 420/810 . . . . . . . . . . . . . . . . . . . . .
2-1
Cable Suspension Diagram and machine weights – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . .
2-2
2.2
Off–loading, preservative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2.2.1
Off–loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2.2.2
The preservative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2.3
Installation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
2.3.1
Installation Plan Demag modular 125/475 and 150/475 . . . . . . . . . . . . . . . . . . .
2-4
2.3.2
Installation Plan Demag modular 150/500 and 200/500 . . . . . . . . . . . . . . . . . . .
2-5
2.3.3
Installation Plan Demag modular 200/560 and 250/560 . . . . . . . . . . . . . . . . . . .
2-6
2.3.4
Installation Plan Demag modular 250/630 and 300/630 . . . . . . . . . . . . . . . . . . .
2-7
2.3.5
Installation Plan Demag modular 350/710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8
2.3.6
Installation Plan Demag modular 350/810 and 420/810 . . . . . . . . . . . . . . . . . . .
2-9
2.3.7
Installation Plan Demag modular 420/800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
2.3.8 2.3.8.1 2.3.8.2
Installation Plan Demag modular 500/900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Plan Demag modular 500/900–2300 and 500/900–3300 . . . . . . . . Installation Plan Demag modular 500/900–6400 . . . . . . . . . . . . . . . . . . . . . . . .
2-11 2-11 2-12
2.3.9 2.3.9.1
Installation Plans Demag modular 650/1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Plan Demag modular 650/1000–3300 with pump aggregate 75kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Plan Demag modular 650/1000–3300 with pump aggregate 90kW, 650/1000–6400 and 650/1000–9500 . . . . . . . . . . . . . .
2-13
2.3.10
Installation Plan Demag modular 800/1120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15
2.4
Foundation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16
2.4.1
Foundation Plan Demag modular 125/475 and 150/475 . . . . . . . . . . . . . . . . . .
2-16
2.4.2
Foundation Plan Demag modular 150/500 and 200/500 . . . . . . . . . . . . . . . . . .
2-17
2.4.3
Foundation Plan Demag modular 200/560 and 250/560 . . . . . . . . . . . . . . . . . .
2-18
2.4.4
Foundation Plan Demag modular 250/630 and 300/630 . . . . . . . . . . . . . . . . . .
2-19
2.4.5
Foundation Plan Demag modular 350/710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-20
2.1.2
2.3.9.2
BA027.01.1.en
2-13 2-14
I
2
Table of contents
2.4.6
Foundation Plan Demag modular 350/810 and 420/810 . . . . . . . . . . . . . . . . . .
2-21
2.4.7
Foundation Plan Demag modular 420/800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-22
2.4.8 2.4.8.1 2.4.8.2
Foundation Plans Demag modular 500/900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foundation Plan Demag modular 500/900–2300 and 500/900–3300 . . . . . . . Foundation Plan Demag modular 500/900–6400 . . . . . . . . . . . . . . . . . . . . . . . .
2-23 2-23 2-24
2.4.9 2.4.9.1
Foundation Plans Demag modular 650/1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . Foundation Plan Demag modular 650/1000–3300 with pump aggregate 75 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foundation Plan Demag modular 650/1000–3300 with pump aggregate 90 kW, 650/1000–6400 and 650/1000–9500 . . . . . . . . . . . . .
2-25
2.4.10
Foundation Plan Demag modular 800/1120 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-27
2.5
Installation and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-28
2.5.1 2.5.1.1 2.5.1.1.1 2.5.1.1.2
Notes for alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soil bearing values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soil bearing values – Demag modular 125/475 up to 350/810 and 420/810 . . Soil bearing values – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . . Number of rag bolts or anti–vibration mounts . . . . . . . . . . . . . . . . . . . . . . . . . . Number of rag bolts or anti–vibration mounts – Demag modular 125/475 up to 350/810 and 420/810 . . . . . . . . . . . . . . . . . . . . . Number of rag bolts or anti–vibration mounts – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . .
2-28 2-29 2-29
Transport protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport protection – Demag modular 125/475 up to 350/810 and 420/810 . Transport protection – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . .
2-32 2-32
Installing and aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing and aligning – Demag modular 125/475 up to 350/810 and 420/810 . . . . . . . . . . . . . . . . . . . . . Installing and aligning – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . .
2-34 2-34
2.6
Flexible anti–vibration Machine Mounts (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-39
2.6.1
Adjusting the Flexible Anti–Vibration Machine Mounts . . . . . . . . . . . . . . . . . . .
2-39
2.7
Connecting the Cooling Water Supply – Water Cooling . . . . . . . . . . . . . . . . . .
2-40
2.7.1
Notes on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-40
2.7.2
Notes for Connecting the Cooling Water Supply . . . . . . . . . . . . . . . . . . . . . . . .
2-41
2.7.3
Water Cooling System – Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-43
2.4.9.2
2.5.1.2 2.5.1.2.1 2.5.1.2.2 2.5.2 2.5.2.1 2.5.2.2 2.5.3 2.5.3.1 2.5.3.2
II
2-25 2-26
2-30 2-31 2-31 2-31
2-33
2-36
BA027.01.1.en
Table of contents
2.7.3.1 2.7.3.2
2
Water Cooling System – Diagram Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Cooling System – Diagram, on machines with separate watercooling circuits (ZE) . . . . . . . . . .
2-44
2.7.4
Hydraulic oil cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-45
2.7.5
Cooling the screw cylinder feed zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-46
2.7.6 2.7.6.1 2.7.6.1.1
Cooling water consumption for hydraulic oil cooling system . . . . . . . . . . . . . . Cooling water consumption (l/h) for machines capacity oil cooler Standard . Cooling water consumption (l/h) for machines capacity oil cooler Standard – Demag modular 125/475 up to 350/810 and 420/810 . . . . . . . . . . . Cooling water consumption (l/h) for machines capacity oil cooler Standard – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . . Cooling water consumption (l/h) for machines ZE...high capacity oil cooler . Cooling water consumption (l/h) for machines ZE...high capacity oil cooler – Demag modular 125/475 up to 350/710 and 420/810 . . . . . . . . . . . . . . . . . . . . . Cooling water consumption (l/h) for machines ZE...high capacity oil cooler – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . .
2-47 2-47
2.7.6.1.2 2.7.6.2 2.7.6.2.1 2.7.6.2.2
2-43
2-47 2-48 2-49 2-49 2-50
2.7.7
Mould Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-51
2.8
Filling with Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-53
2.8.1
Hydraulic Oil – tank capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-54
2.9
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-55
2.9.1
Notes on electrical connection – clamping unit / injection unit – Demag modular 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . .
2-55
2.9.2
Notes on electrical connection – power supply . . . . . . . . . . . . . . . . . . . . . . . . .
2-56
2.9.3
Check direction of rotation of pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-57
2.9.4 2.9.4.1 2.9.4.2 2.9.4.3 2.9.4.4 2.9.4.5 2.9.4.6 2.9.4.7 2.9.4.8 2.9.4.9 2.9.4.10 2.9.4.11
Electrical installation data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 125/475 and 150/475 . . . . . . . . . . Electrical installation data Demag modular 150/500 and 200/500 . . . . . . . . . . Electrical installation data Demag modular 200/560 and 250/560 . . . . . . . . . . Electrical installation data Demag modular 250/630 and 300/630 . . . . . . . . . . Electrical installation data Demag modular 350/710 . . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 350/810 . . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 420/810 . . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 420/800 . . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 500/900 . . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 650/1000 . . . . . . . . . . . . . . . . . . . . Electrical installation data Demag modular 800/1120 . . . . . . . . . . . . . . . . . . . .
2-58 2-58 2-59 2-60 2-61 2-62 2-63 2-64 2-65 2-66 2-67 2-68
2.10
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-69
BA027.01.1.en
III
Commissioning and Disassembly
2
Commissioning and Dismantling
2.1
Cable Suspension Diagrams and machine weights
2.1.1
Cable Suspension Diagram and machine weights – Demag modular 125/475 up to 350/810 and 420/810
2
b
a
system 150/475–440
Picture 1: Cable suspension diagram Demag modular 125/475 up to 350/810 and 420/810
Attention! Do not lift the machine without transport protection chap. 2.5.2
Machine Type
Machine weight without hydraulic oil
Attachment–Point a/b
[ kg ] Demag modular 125/475 Demag modular 150/475 Demag modular 150/500 Demag modular 200/500 Demag modular 200/560 Demag modular 250/560 Demag modular 250/630 Demag modular 300/630 Demag modular 350/710 Demag modular 350/810 Demag modular 420/810
6600 6800 7800 8000 10600 11200 13800 14600 16000 21000 21000
67 / 63 67 / 63 67 / 63 67 / 63 80 / 68 80 / 68 80 / 68 80 / 68 80 / 68 75 / 114 75 / 114
Table 1: Machine weights
BA027.01.1.en
2-1
2
2.1.2
Commissioning and Disassembly
Cable Suspension Diagram and machine weights – Demag modular 420/800 and 500/900 up to 2000/1800
b
a
Ra
!
Picture 2: Cable suspension diagram Demag modular 420/800 and 500/900 up to 2000/1800
Clamping unit 420
500
13600
16500
Weight without hydraulic oil
Attachment–Point a/b
mm 75 /114 75 /114
650
800
1000
1300
1500
2000
25700 33500 52500 68000 74000 100000 80 /48
80 /48
80 /48
80 /48
80 /48
50
Table 2: Weights Clamping unit
Injection unit 1450
2300
3300 I
3300 II
6400
9500
11500
16000
Weight without hydraulic oil
4100
4400
5400
7100
7800
9700
20000
21000
Attachment–Point a/b
mm
Ø 48
Ø 48
Ø 48
Ø 65
Ø 65
Ø 65
–
–
Transport rod
mm
–
–
–
–
–
–
Ø 133
Ø 133
MB I 45–75 kW
MB II 90 kW
MB II 75–110 kW
MB III
Table 3: Weights Injection unit
2-2
BA027.01.1.en
Commissioning and Disassembly
2.2
Off–loading, preservative
2.2.1
Off–loading
2
When the injection moulding machine has been delivered remove all packing. Check that the machine is undamaged and in good condition. Written acknowledgement of any damage in transit must be made by the carrier. The manufacturer, Demag Ergotech GmbH – Schwaig factory, must be notified immediately, so that a claim can be made on the transport insurance. A crane with sufficient lifting power is require for off–loading. For machine weights see chap. 2.1. Should the machine need to be moved around within the factory without the aid of a crane, suitable rollers should be used in the correct manner. Note: The manufacturer accepts no responsibility for any damage which occurs in transit.
2.2.2
The preservative All exposed machine parts such as piston rods, tie bars, and platen areas are treated with an anti–corrosive agent prior to delivery of the machine. This creates a fine protective film which can combine with the lubricants on the bearing surfaces and with the hydraulic oil without any problem. Attention! Therefore, please leave the anti–corrosive agent on all areas requiring protection where it does not interfere with the handling of the machine. This provides your machine with essential protection against aggressive and corrosive environmental influences. The preservative should be removed with a cloth, but only if absolutely necessary. Attention! Do not use solvents to remove the anti–corrosive agent!
BA027.01.1.en
2-3
2
Commissioning and Disassembly
2.3
Installation Plans
2.3.1
Installation Plan Demag modular 125/475 and 150/475
!
2240 1100
330
1585 H
985
85
750
665
275
1500
150
630
D
800
710
2077 450
950
345
600
1295 70
52 122
280
520 730
4200
425
D
460
4910 reference point for foundation mould mounting surfaces (fixed platen)
Connecting the Cooling Water Supply
A,B 185
2000
K
System 125/475
255
Injection unit
together
separate *)
A
Cooling water inlet
1”
1”
B
Cooling water outlet
1”
1”
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Pg 36 + Pg 42
H
K
EE 320
218
2042
EE 440
436
2057
EE 610
661
2057
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
2-4
BA027.01.1.en
2
Commissioning and Disassembly
2.3.2
Installation Plan Demag modular 150/500 and 200/500
! 1630
2340
2520 1240
330
H
985
85
770
690
275
1500
2077 810
450
950
320
1320
555
250
70
52 D
900
710
315
122 570 750
4480 5190
450
D
485
reference point for foundation mould mounting surfaces (fixed platen) A,B 185
2000
K
System 150/500
220
Injection unit
Connecting the Cooling Water Supply together
separate *)
A
Cooling water inlet
1”
1”
B
Cooling water outlet
1”
1”
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Pg 36 + Pg 42
H
K
EE 440
436
2082
EE 610
661
2082
EE 840
1036
2092
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
BA027.01.1.en
2-5
2
Commissioning and Disassembly
Installation Plan Demag modular 200/560 and 250/560
! 1500
2540
2845 330
1390
1730 H
985
85
820
740
275
2.3.3
365
50
960
D
1000
785
450
2077
K 950
310
555
1350 70
52 122 670 800
4930 5715
495 530
D
reference point for foundation mould mounting surfaces (fixed platen) A,B 185
2000
System 200/560
215
Injection unit
Connecting the Cooling Water Supply together
separate *)
A
Cooling water inlet
1”
1”
B
Cooling water outlet
1”
1”
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Pg 36 + Pg 42
H
K
EE 610
511
2112
EE 840
880
2122
EE 1450
1403
2257
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
2-6
BA027.01.1.en
2
Commissioning and Disassembly
2.3.4
Installation Plan Demag modular 250/630 and 300/630
! 2910
3230 330
1625
1890
H
985
900
85
820
275
1800
70
50
2077
K
D 1040
450
950
300
2097 2000 1385 520
2232
System 250/630
1200
890
52
420
780
122 5580
880 580
6470
615
D
reference point for foundation mould mounting surfaces (fixed platen) Connecting the Cooling Water Supply
185
A,B
220
Injection unit
together
separate *)
A
Cooling water inlet
1”
1”
B
Cooling water outlet
1”
1”
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Pg 36 + Pg 42
H
K
EE 840
550
2157
EE 1450
1073
2292
EE 2300
1555
2322
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
BA027.01.1.en
2-7
2
Commissioning and Disassembly
2.3.5
Installation Plan Demag modular 350/710
! 2910
3230 1625
985
330
1975
H
985
85
820
275
1800
70
50
D 1370
2077
K 450
950
300
2135 2000 1405 520
2232
System 350/710
52 122 780
1200
560
420
5910
965
6470
580
D
615
reference point for foundation mould mounting surfaces (fixed platen)
185
A,B
280
Injection unit
Connecting the Cooling Water Supply together
separate *)
A
Cooling water inlet
1”
1”
B
Cooling water outlet
1”
1”
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Pg 36 + Pg 42
H
K
EE 840
580
2177
EE 1450
1103
2312
EE 2300
1585
2342
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
2-8
BA027.01.1.en
2
Commissioning and Disassembly
Installation Plan Demag modular 350/810 and 420/810
! 1800
330
3725 1870
3685
2180
H
985
940
1070
85
275
2.3.6
70
1740
2077 450
950
370
50
950
L K
2315 2000 1530 535
M 827
1200
645
D
7095
510
N 940
897
1050 700
7740
D
735
reference point for foundation mould mounting surfaces (fixed platen) Connecting the Cooling Water Supply
185
A,B
together
separate *)
A
Cooling water inlet
1”
1”
B
Cooling water outlet
1”
1”
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Hmax.
K
L
M
N
EE 1450
478
2437
1802
200
–
EE 2300
916
2467
2322
200
–
EE 3300
1745
2497
2357
470
398
170
Injection unit
Pg 36 + Pg 42
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
BA027.01.1.en
2-9
2
Commissioning and Disassembly
2.3.7
Installation Plan Demag modular 420/800
! 1300
2180
4300 H
G
85
1070 940
675
390
K
2275
1500
2200
200
1650 400
400
70
160
300
1960
500
525
633 700
D
1100
750
1250
E F reference point for foundation mould mounting surfaces (fixed platen)
Connecting the Cooling Water Supply together separate *) 1” 1” 1 1/2 ” 1”
A,B Cooling water inlet Cooling water outlet
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
E
F
G
H
K
EE 1450
7165
7915
3615
447
2407
EE 2300
7165
7915
3615
928
2437
EE 3300
7605
8355
4055
1280
2402
255
A B
D
690 Injection unit
450
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
2-10
BA027.01.1.en
2
Commissioning and Disassembly
2.3.8
Installation Plan Demag modular 500/900
2.3.8.1
Installation Plan Demag modular 500/900–2300 and 500/900–3300
! 1300
2315
4610
1135 1010
85
H
G
K
390 2275
675
1500
2200
200
1700 430
400
70
180
120
400
588
633
2190
1100
D
825
E
800
1395
F reference point for foundation mould mounting surfaces (fixed platen) Connecting the Cooling Water Supply together separate *) 1” 1” 1 1/2 ” 1”
A,B Cooling water inlet Cooling water outlet
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
E
F
G
H
K
EE 2300
7425
8225
3615
935
2437
EE 3300
7865
8665
4055
1280
2402
615
Injection unit
450
255
D
A B
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
BA027.01.1.en
2-11
2
Commissioning and Disassembly
2.3.8.2
Installation Plan Demag modular 500/900–6400
!
2315
4610
1300
430
397
5730
85
1135 1010
675
2432
390 2275
1500
2200
200
1700
400
70
180
D1
414
1766 1395
9540
800
588 825
1100
2190
120
D2
A,B 52
10340 reference point for foundation mould mounting surfaces (fixed platen) A,B on non–operator side Connecting the Cooling Water Supply
"# "
191
A,B
835
together
separate *)
1”
1”
1 1/2 ”
1”
A
Cooling water inlet
B
Cooling water outlet
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
918 D1
Electrical connection Supply I
D2
Electrical connection Supply II
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
2-12
BA027.01.1.en
2
Commissioning and Disassembly
Installation Plans Demag modular 650/1000 Installation Plan Demag modular 650/1000–3300 with pump aggregate 75kW
! 1900
2475
5327 2053 500
85
4055
1280
2402 675
1500
2200
2480
1220 1085
350 2275
2.3.9 2.3.9.1
400
70
149 355
400
670
633
2472
D
1300
972
950 1560
8410 9382 reference point for foundation mould mounting surfaces (fixed platen)
Connecting the Cooling Water Supply
255
A,B
D
615
450
together
separate *)
1”
1”
1 1/2 ”
1”
A
Cooling water inlet
B
Cooling water outlet
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D
Electrical connection
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
BA027.01.1.en
2-13
2
Commissioning and Disassembly
Installation Plan Demag modular 650/1000–3300 with pump aggregate 90kW, 650/1000–6400 and 650/1000–9500
! 1900
2475
5327 500
2053
H
K 675
1500
2200
2480
1220 1085
85
G
350 2275
2.3.9.2
400
70
149
355
D2
1300
2472 972
D1 1766
A,B 52 414
670 950
E
1560
F reference point for foundation mould mounting surfaces (fixed platen) A,B on non–operator side Connecting the Cooling Water Supply together separate *) 1” 1” 1 1/2 ” 1”
"# "
191
A,B
835
Injection unit EE 3300 EE 6400 EE 9500
918
A B
Cooling water inlet Cooling water outlet
*)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D1 D2
Electrical connection Supply I Electrical connection Supply II
E
F
G
H
K
9385 10085 10798
10397 11057 11770
5030 5730 6443
305 397 419
2402 2432 2452
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
2-14
BA027.01.1.en
2
Commissioning and Disassembly
2.3.10
Installation Plan Demag modular 800/1120
! 1900
2665 5850 580
2190
H
G
1310 1185
85
305 2350
K 570
1500
2275
2585
295
70
163 2882
240
D2
1300
995
D1
A,B 52 414
725 1120
1766
1690
E F reference point for foundation mould mounting surfaces (fixed platen)
"# "
191
A,B
835
Injection unit
Connecting the Cooling Water Supply together separate *) 1” 1” 1 1/2 ” 1”
A B *)
Cooling water inlet Cooling water outlet 1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
D1
Electrical connection Supply I
D2
Electrical connection Supply II
918
E
F
G
H
K
EE 6400
10585
11580
5730
397
2432
EE 9500
11298
12292
6443
419
2452
Note: The machine must have a clearance of approx. 1.5m on all sides, including all extended or overhanging units (squeezing danger).
BA027.01.1.en
2-15
2
Commissioning and Disassembly
2.4
Foundation Plans
2.4.1
Foundation Plan Demag modular 125/475 and 150/475
300
200
100
m
n 1320
513
1120
1280
ÄÄ ÄÄ
252
177
367
A C2
D2
G1
G2
228
280
$ %
178
360
D1
560
385
C1
1400
A
660
F1
f 217
4165
218
4600 M20
M20X1,5
&
A–A
A–A ' (
53 – 68
400
$ ))) ' & %( !( *
+ , -
Ø160
200 Rag bolt DIN 529
2-16
e
&
supporting surface
structured steel material waxed floor Q 222
BA027.01.1.en
Commissioning and Disassembly
Foundation Plan Demag modular 150/500 and 200/500 100
300
m
200
2.4.2
2
200
1500
1300
553
1120
ÄÄ ÄÄ
265
n 527
D1
C1
730
A
G1
355
1500
370
A
G2
315 630
F1
$ % D2
C2
250
200
f
278
4445
277
5000 M20
M20X1,5
&
A–A
53 – 68
A–A
400
$ ))) ' (
' & %( !( *
+ , Ø160
200
Rag bolt DIN 529
BA027.01.1.en
e
&
supporting surface
structured steel material waxed floor Q 222
2-17
2
Commissioning and Disassembly
Foundation Plan Demag modular 200/560 and 250/560 100
350
m
200
2.4.3
n 1950
1180
1420
ÄÄ ÄÄ
548
245
195
302
$ %
G2
245
195
380
D2
730
A C2
G1
365
380
D1
1600
A C1
830
F1
f 252
4895
253 5400
M20
M20X1,5
& A–A
A–A ' (
53 – 68
400
$ ))) ' & %( !( *
+ , Ø200
200
Rag bolt DIN 529
2-18
e
&
supporting surface
structured steel material waxed floor Q 222
BA027.01.1.en
Commissioning and Disassembly
Foundation Plan Demag modular 250/630 and 300/630 100
207
327
n 1300
930
1615
1365
563
ÄÄ ÄÄ
272
400
m
200
2.4.4
2
C1
D1
E1
D2
E2
940
A C2
$ %
G1
380
1750
395
A
G2
420 840
F1
258
208
f 5545
277
278
6100 M20
M20X1,5
&
A–A
400
$ ))) ' (
' & %( !( *
+ , -
60 – 72
A–A
Ø228
300
Rag bolt DIN 529
BA027.01.1.en
e
&
supporting surface
structured steel material waxed floor Q 222
2-19
2
Commissioning and Disassembly
Foundation Plan Demag modular 350/710
100
400
m
200
2.4.5
1270
1615
1365
563
ÄÄ ÄÄ
357
207
327
n 1300
D1
E1
A C2
D2
E2
G1
$ % G2
258
208
380
C1
840
940
1835
A
420
480
F1
f 277
5885
278
6440
&
M20X1,5
A–A
400
$ ))) ' (
A–A 60 – 72
M20
' & %( !( *
+ , -
Ø228 300
Rag bolt DIN 529
2-20
e
&
supporting surface
structured steel material waxed floor Q 222
BA027.01.1.en
2
Commissioning and Disassembly
Foundation Plan Demag modular 350/810 and 420/810 100
450
m
200
2.4.6
1640
620
1790
1365
563
ÄÄ ÄÄ
357
207
327
n 1320
D1
E1
D2
E2
F1
A
B
G2
C2 A F2
f 277
240 298
A
448
H1
$ %
A
1120
A
475
C1
1020
2350
A
510
575
A G1
A H2
B
7070
278
7625
&
A–A
M24 B–B
250
400 350
Rag bolt DIN 529
BA027.01.1.en
e
250
&
A–A
M24X1,5
e
supporting surface
60–72
M24
$ ))) ' & %( !( *
+ , M24X1,5
B–B
Ø228
60–72
' (
Ø228
structured steel material waxed floor Q 222
2-21
2
Commissioning and Disassembly
Foundation Plan Demag modular 420/800 120
500
m
300
2.4.7
1185
ÄÄ ÄÄ ÄÄ ÄÄ ÄÄ ÄÄ
B B
BD
B
B
1
B
E1
U1
A
A
$ %
C2 D2 B
B
B
B
E2 B
B
U2
288
W1
A
W2 A 2485
1100 450
450
3500
280
A
A
B
f
A V1
210
525
625 1050
1250
2000
325
A
B C1
1205
1320
M
900
n 1424
1626
470 940
213
442
3285 L
' (
A–A
M24 B–B
250
400 350
Rag bolt DIN 529 Injection unit
e
e
250
&
A–A
M24X1,5
supporting surface
60–72
M24
$ ))) ' & %( !( *
+ , M24X1,5
B–B
Ø228
60–72
&
Ø228
structured steel material waxed floor Q 222
EE 1450
EE 2300
EE 3300
L
7700
7700
8140
M
1093
1093
1533
2-22
BA027.01.1.en
2
Commissioning and Disassembly
2.4.8
Foundation Plans Demag modular 500/900
2.4.8.1
Foundation Plan Demag modular 500/900–2300 and 500/900–3300 500
300
120
m
n
ÄÄ Ä ÄÄ ÄÄ Ä ÄÄ
588
698 1176
1396
2100
252
A
B
C1
B
B D 1 E1
B
B
B
C2 D2 B
B B
B
E2
U1
A
A
V1
B
B
B
U2
W1
A
A
A
W2 A 2485
303 1100 480
280
A
$ %
B
f
1205
1320
1185
M
210
1454
900
1816
470 940
226
467
450
3760
3285 L
&
$ )))
' ( M24 B–B 250
400
M24X1,5
350 Rag bolt DIN 529
Injection unit L M
BA027.01.1.en
e
250 &
e
supporting surface
A–A 60–72
A–A
' & %( !( *
+ , M24X1,5
60–72
M24
B–B
Ø228
Ø228
structured steel material waxed floor Q 222
EE 2300
EE 3300
7960 1108
8400 1548
2-23
2
Commissioning and Disassembly
Foundation Plan Demag modular 500/900–6400
120
500
m
300
2.4.8.2
n 2070
ÄÄ Ä ÄÄ Ä
1176
588
698
2185
1396
337
A
B C1 B B B
B
B
D1 E1
B
B
E2
U1
A
A
B
C2 D2 B
2470
B
B
B
B
V1
A
ÄÄ ÄÄ A
A
$ % B U2
B
V2 W2
B
W1 1735
1283
1454
985
1816
470 940
226
467
B
303
f
1100 480 280
225
3760
5000 9770 $ )))
' (
' & %( !( *
+ , M24X1,5
M24 B–B
350
Rag bolt DIN 529
2-24
e
250
&
A–A
M24X1,5 250
400
A–A
e
supporting surface
60–72
M24
60–72
&
B–B
Ø228
Ø228
structured steel material waxed floor Q 222
BA027.01.1.en
2
Commissioning and Disassembly
2.4.9
Foundation Plans Demag modular 650/1000
2.4.9.1
Foundation Plan Demag modular 650/1000–3300 with pump aggregate 75 kW
600
300
120
m
n
B
C2
E1 F1
B
B B
B
D2
B
B B
E2 F2
B
A
U1
A
B B B B B G2
A
V1
U2
W1
A
A
$ %
B
A
W2 A 2485
149 450
1300 548
250
1205
ÄÄ Ä ÄÄ ÄÄ A
B B G1
B f
1185
1320
D1
251 1394
1611
900
670
780 1340
B
C1
B B
989
210
B
85 1560
2095
1171
470 940
226
399
3285
4320 8900
& $ ))) ' ( M24 B–B 250
400
M24X1,5
350
Rag bolt DIN 529
BA027.01.1.en
e
250
&
e
supporting surface
A–A
60–72
A–A
' & %( !( *
+ , M24X1,5
60–72
M24
B–B
Ø228
Ø228
structured steel material waxed floor Q 222
2-25
2
Commissioning and Disassembly
Foundation Plan Demag modular 650/1000–3300 with pump aggregate 90 kW, 650/1000–6400 and 650/1000–9500 120
600
m
300
2.4.9.2
n
B
B
D1
C2
E1 F1
B
B B
D2
B
251 M
B
E2 F2
B
ÄÄ Ä ÄÄ Ä A
B B G1
A
U2
B
ÄÄ ÄÄ A
W1
A
B
V2 W2 B
149
1300 548
250
V1
$ % B
B
B
A
U1
A
B B B B B G2 B
f
2470
2070
1735
1611
985
670 1340
B
C1
B B
989
470 940
1171
B 780
1560
2265
255
226
399
225
4320
5000 L
& $ ))) ' ( M24 B–B 250
400
M24X1,5
350 Rag bolt DIN 529 Injection unit
e
e
250 &
supporting surface
A–A
60–72
A–A
' & %( !( *
+ , M24X1,5
60–72
M24
B–B
Ø228
Ø228
structured steel material waxed floor Q 222
EE 3300
EE 6400
EE 9500
L
9958
10570
11306
M
512
1124
1860
2-26
BA027.01.1.en
2
Commissioning and Disassembly
Foundation Plan Demag modular 800/1120
120
600
m
300
2.4.10
C1
B
D1
B C2 B
BE
B
B
B
1 F1
B
D2
B
B f
2470
ÄÄ Ä ÄÄ ÄÄ Ä ÄÄ A
B G1
U1
A
B B
G2 E2 B F2 B B 163 1300 608
280
2070
A V1
A
A
A
$ % B U2
B
V2 W2
B
W1 1735
B
282 M
985
1252
B B
n 1626
470 940
725
845
B
1450
1690
235
190
226
443 1304
B
225 5000
4790 L $ )))
' (
A–A
' & %( !( *
+ , -M24X1,5
M24 B–B 400
M24X1,5 B–B
250 350 Rag bolt DIN 529 Injection unit L M
BA027.01.1.en
e
250 &
e
Ø228
supporting surface
A–A 60–72
M24
60–72
&
Ø228
structured steel material waxed floor Q 222
EE 6400
EE 9500
11120 1158
11856 1894
2-27
2
Commissioning and Disassembly
2.5
Installation and Alignment
2.5.1
Notes for alignment If the machine is installed on a reinforced concrete floor either at ground level or higher, then special foundation preparation may not apply. Proof of sufficient load bearing capacity can only be given by a qualified structured engineer. If, however, the machine is installed on normal indoor flooring or solid ground, then foundations must be prepared. The foundation dimensions given in chap. 2.4 should be taken as guidelines for structurally sound ground. A structural engineer must confirm that they suit the actual conditions. B25 concrete to DIN 1045 should be used for the foundations. Calculations for maximum surface pressure between the machine supports and the concrete foundation can be made using chap. 2.5.1.1. The machine is fixed to the ground or to the foundations using rag bolts as per the foundation plan in chap. 2.4. Note: The machines can also be installed on flexible anti–vibration mounts, supplied as additional equipment, see chap. 2.6. Due account must be taken of the concerntation of load in the machine mounts. The maximum loading should be multiplied accordingly.
2-28
BA027.01.1.en
2
Commissioning and Disassembly
2.5.1.1 Soil bearing values 2.5.1.1.1 Soil bearing values – Demag modular 125/475 up to 350/810 and 420/810 Machine Type
Without anti–vibration mounts
With anti–vibration mounts
Surface pressure
2]
Soil bearing values [N] (Surface pressure 2]) anti–vibration mounts C1/C2
D1/D2
E1/E2
F1
G1/G2
H1/H2
Demag modular 125/475
15
11730 (68)
16270 (94)
–
7010 (41)
7010 (41)
–
Demag modular 150/475
15
12160 (70)
16780 (97)
–
7010 (41)
7010 (41)
–
Demag modular 150/500
20
14980 (87)
21110 (122)
–
7600 (44)
7600 (44)
–
Demag modular 200/500
20
15430 (89)
21690 (125)
–
7600 (44)
7600 (44)
–
Demag modular 200/560
20
24050 (88)
28630 (105)
–
8550 (31)
8550 (31)
–
Demag modular 250/560
20
25280 (93)
30360 (111)
–
8550 (31)
8550 (31)
–
Demag modular 250/630
25
19380 (75)
16990 (66)
34130 (133)
9990 (39)
9990 (39)
–
Demag modular 300/630
25
20610 (80)
17630 (69)
36260 (141)
9990 (39)
9990 (39)
–
Demag modular 350/710
30
24480 (95)
18920 (74)
39860 (155)
9860 (38)
9860 (38)
–
Demag modular 350/810
30
15350 (60)
26170 (102)
51840 (202)
5550 (22)
19850 (77)
9990 (39)
Demag modular 420/810
30
15350 (60)
26170 (102)
51840 (202)
5550 (22)
19850 (77)
9990 (39)
*) see foundation plan chap. 2.4 Table 4: Soil bearing values and surface pressure
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Commissioning and Disassembly
2.5.1.1.2 Soil bearing values – Demag modular 420/800 and 500/900 up to 2000/1800 Soil bearing values – Without anti–vibration mounts Soil bearing values [N] Clamping unit
Injection unit
Surface pressure 30 30 30 30 10 10 10 10 10 10
SE 420/800 SE 500/900 SE 650/1000 SE 800/1120 EE 1450 EE 2300 EE 3300 I EE 3300 II EE 6400 EE 9500
2]
MB I 45 – 75 kW MB II 90 kW MB II 75 – 110 kW
Table 5: Surface pressure
Soil bearing values – Demag modular 420/800 and 500/900 up to 2000/1800 – continuation
Soil bearing values – With anti–vibration mounts Soil bearing values Surface pressure 2] )
Clamping unit
SE 420/800 SE 500/900 SE 650/1000 SE 800/1120 Injection unit
C1/C2 25500 (99) 29670 (115) 33460 (130) 45140 (176)
D1/D2 24200 (94) 31170 (121) 22820 (89) 30790 (120)
E1/E2 43800 (170) 55170 (215) 41920 (163) 49830 (194)
anti–vibration mounts F1/F2 G1/G2 H1/H2 K1/K2 – – – –
L1/L2 –
M1/M2 –
N1/N2 –
–
–
–
–
–
–
–
36640 (143) 47860 (186)
36640 (143) 47860 (186)
–
–
–
–
–
–
–
–
–
–
Soil bearing values Surface pressure 2] )
EE 1450 EE 2300 EE 3300 I EE 3300 II
U1/U2 9568 (37) 10168 (40) 12168 (51) 14283 (56)
anti–vibration mounts V1 V2 W1/W2 9568 (37) – 9568 (37) 10168 (40) – 10168 (40) 12168 (51) – 12168 (51) 14283 (56) 14283 (56) 14283 (56)
EE 6400 EE 9500
14950 (58) 18117 (67)
14950 (58) 18117 (67)
X1 – – – –
MB I 45 – 75 kW MB II 90 kW
14950 (58) 14950 (58) – 18117 (67) 18117 (67) – *) see foundation plan chap. 2.4
MB II 75 – 110 kW
Table 6: Soil bearing values and surface pressure
2-30
BA027.01.1.en
Commissioning and Disassembly
2
2.5.1.2 Number of rag bolts or anti–vibration mounts 2.5.1.2.1 Number of rag bolts or anti–vibration mounts – Demag modular 125/475 up to 350/810 and 420/810 Machine Type
Rag bolts Quantity
With anti–vibration mounts Quantity
Demag modular 125/475
4
7
Demag modular 150/475
4
7
Demag modular 150/500
4
7
Demag modular 200/500
4
7
Demag modular 200/560
4
7
Demag modular 250/560
4
7
Demag modular 250/630
6
9
Demag modular 300/630
6
9
Demag modular 350/710
6
9
Demag modular 350/810
7
12
Demag modular 420/810
7
12
Table 7: Number of rag bolts or anti–vibration mounts
2.5.1.2.2 Number of rag bolts or anti–vibration mounts – Demag modular 420/800 and 500/900 up to 2000/1800 Clamping unit 420
BA027.01.1.en
500
650
800
1000
1300
1500
2000
2-31
2
Commissioning and Disassembly
Rag bolts With mounts
anti–vibration
Quantity
6
6
10
10
20
20
20
32
Quantity
6
6
10
10
20
20
20
32
Table 8: Number of rag bolts or anti–vibration mounts
Injection unit
Rag bolts With mounts
anti–vibration
1450
2300
3300 I 3300 II
Quantity
5
5
5
Quantity
5
5
5
MB I 45 – 75 kW
6400
9500
6
6
6
7
7
6
6
6
7
7
MB II 90 kW
MB II 75 – 110 kW
11500 16000
MB III
Table 9: Number of rag bolts or anti–vibration mounts
2.5.2 2.5.2.1
Transport protection Transport protection – Demag modular 125/475 up to 350/810 and 420/810
b d c *. /0 1 /0 -
a c
d
*. /0 /0 2 -
b
Picture 3: Transport Protection – Demag modular 125/475 up to 350/810 and 420/810
2-32
BA027.01.1.en
Commissioning and Disassembly
2
Clamping unit When the machine is in transit, the end plate on the clamping unit is secured to the machine bed with bolts a. Injection unit with sliding ball bearing When the machine is in transit, the injection unit is secured to the machine bed with an angle or plate d and bolts b + c. Attention! Before putting the machine into operation these bolts must be removed!
BA027.01.1.en
2-33
2
2.5.2.2
Commissioning and Disassembly
Transport protection – Demag modular 420/800 and 500/900 up to 2000/1800
" #$ % "
b a c
c
a
b
*. /0 /0 3 -
a
b
c
* " ## % " #& Picture 4: Transport protection – Demag modular 420/800 and 500/900 up to 2000/1800
When the machine is in transit, the injection unit is secured to the machine bed with an angle or plate a and bolts b + c.
Attention! Before putting the machine into operation the transport protection must be removed!
2-34
BA027.01.1.en
Commissioning and Disassembly
2.5.3 2.5.3.1
2
Installing and aligning Installing and aligning – Demag modular 125/475 up to 350/810 and 420/810
k
m
m
m
m
Picture 5: Installing and aligning
Set down the machine on the appropriately prepared seel–reinforced concrete floor or on the foundation. Set precisely by shimming when using rag bolts, or by adjustment srews when elastic machine supports (see chap. 2.6) are used. A precision water balance m should be used for measurement. Supporting points for the balance are the tie–bars crosswise and longitudinally. Level firstly crosswise and then longitudinally ! For the crosswise measuring an auxiliary ruler k is necessary. Permitted tolerances: Crosswise
0.16 mm / m
longitudinal
0.24 mm / m
Filling the machine with hydraulic oil (see chap.2.8) and checking the setting. Any deviation must be corrected!
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Commissioning and Disassembly
Installing and aligning – Demag modular 125/475 up to 350/810 and 420/810 – continuation When alignment is completed put in concrete bolts and underseal the supporting surface of the machine with liquid concrete. Attention! Wait until the cement has set hard before tightening the nuts on the concrete bolts. Put on lock nuts where anti – vibration mounts are being used. Attention! In order to prevent damage to the machine by possible setting of the foundation, we recommend a re–check of the machine alignment after a four week operating period. We also recommend that the machine be checked for correct alignment every twelve months.
2-36
BA027.01.1.en
Commissioning and Disassembly
2.5.3.2
2
Installing and aligning – Demag modular 420/800 and 500/900 up to 2000/1800
Picture 6: Alignment of clamping unit
Clamping unit Set down the clamping unit on the appropriately prepared seel– reinforced concrete floor or on the foundation. Set precisely by shimming when using rag bolts, or by adjustment srews when elastic machine supports (see chap. 2.9) are used. A precision water balance m should be used for measurement. Supporting points for the balance are the tie–bars crosswise and longitudinally. Level firstly crosswise and then longitudinally ! For the crosswise measuring an auxiliary ruler k is necessary. Permitted tolerances:
BA027.01.1.en
Crosswise
0.16 mm / m
longitudinal
0.24 mm / m
2-37
2
Commissioning and Disassembly
Installing and aligning – Demag modular 420/800 and 500/900 up to 2000/1800 – continuation e
a
b ##'
#$
Picture 7: Alignment of injection unit
Injection unit Position injection unit against clamping unit so that the set pins a and the bores fit together at the making surface. Note: During installation with foundation screws, the foundation screws must be instslled into the holes in the machine bed, before the injection unit is placed on the foundation. Insert bolts b. Do not yet righten. Set precisely by shimming when using rag bolts, or by adjustment screws when elastic machine supports ( see chap. 2.9 ) are used. A precision water balance m should be used for measurement. Supporting points for the balance are the guides crosswise and longitudinally. Level firstly crosswise and then longitudinally ! For the crosswise measuring an auxiliary ruler is necessary. Permitted tolerances:
2-38
Crosswise
0.30 mm / m
longitudinal
0.24 mm / m
BA027.01.1.en
Commissioning and Disassembly
2
Installing and aligning – Demag modular 420/800 and 500/900 up to 2000/1800 – continuation The precise position of the nozzle serves as aprecise indicator of the position of the injection unit. The nozzle centre must not be misaligned from the centre of the stationary mould platen by more than " 0,2 mm . Tighten bolts b. Then re–connect all hydraulic connections. Electrical connection (see chap. 2.8) Fill machine with hydraulic oil (see chap. 2.7) and check the exact levelling. On deviations it must be relevelled in any cases ! When alignment is completed concrete bolts and underseal the supporting surface of the machine with liquid concrete. Attention! Wait until the cement has set hard before tightening the nuts on the concrete bolts! Connect the piston rod to the stationary platen by tightening of screw e (Tightening Torque, see Table). Machine Type Demag modular 420/800 Demag modular 500/900 Demag modular 650/1000 Demag modular 800/1120 Demag modular 1000/1400 Demag modular 1300/1560 Demag modular 1500/1560 Demag modular 2000/1800
Tightening Torque M1 (Nm) 400 400 400 400 400 400 400 560
Put on lock nuts where anti–vibration mounts are being used. Attention! In order to prevent damage to the machine by possible setting of the foundation, we recommend a re–check of the machine alignment after a four week operating period. We also recommend that the machine be checked for correct alignment every twelve months.
BA027.01.1.en
2-39
2
2.6
Commissioning and Disassembly
Flexible anti–vibration Machine Mounts (ZE) 2
S
1
ÄÄÄÄÄ ÄÄÄÄÄ
S = displacement distance 15 mm Picture 8: Flexible Machine Mounts
Demag injection moulding machines can be fitted with flexible machine mounts. The damping effect of the mounts assists quiet machine operation. When flexible machine mounts are fitted, the machine must not also be anchored to the ground by rag bolts. See foundation Plans chap. 2.4. If the machine is fitted with flexible mounts, less area is required for the foundations. The resulting increase in surface pressure can be seen from Table in chap. 2.5. Note: All supply – and discharge lines to and from the machine, such as cooling water lines, must be flexible.
2.6.1
Adjusting the Flexible Anti–Vibration Machine Mounts Release lock nut 2. Unscrew levelling screw 1 until the machine mounts reach their minimum height. Align the machine by adjusting levelling screw 1 on all machine mounts. Attention! When aligning the machine using levelling screw 1, the maximum displacement distance of 15mm must not be exceeded if damage to the machine mounts is to be avoided.
2-40
BA027.01.1.en
Commissioning and Disassembly
2.7
Connecting the Cooling Water Supply – Water Cooling
2.7.1
Notes on the cooling system
2
The machines may equally well be used with an open cooling circuit or a closed cooling circuit. Note: It is essential that clean water is used for the cooling of our machines. If cooling water is taken from streams or ponds and not filtered, foreign matter can seriously reduce cooling capacity and even block the machine cooling system and the control valves for the oil cooling and electrical drives, which can cause damage to the cooled components. It is therefore essential to use a suitable filter if the cooling water is contaminated. Additions, as e.g. antifreezing solution seriously reduce cooling capa– city. Attention! Operation with sea–water is not permissible. Open cooling system Operation of the machine with an open cooling system may, if the water is hard, cause an increased build–up of chalk, so that frequent descaling may be necessary. Because frequent descaling imposes a burden on the components in the circuit, sind die Vorschriften zum Entkalken einzuhalten. (see chap. 6.14.1) Closed cooling system With a closed cooling circuit with normal additives, descaling is not usually required. Coolants Only ordinary commercially available coolants may be used. Any additives must be copper– and aluminium–compatible. The pH value of the coolant should be between 6 and 9.5.
BA027.01.1.en
2-41
2
2.7.2
Commissioning and Disassembly
Notes for Connecting the Cooling Water Supply The cooling water connections are made on the inlet and outlet distribution points on the front face injection unit. For location on the machine see installation plans, chap. 2.3. Connections: Internal thread Connecting the Cooling Water Supply together separate *) "
125/475 – 350/810, 420/800, 420/810 500/900 – 2000/1800 R1” R1” R1” R1” R 1 1/2 ” R1”
Cooling water inlet Cooling water outlet *)
1x mould cooling and 1x hydraulic oil cooling/feed zone cooling (Option)
We recommend a flexible hose line with shut–off valve. The maximum water pressure of 8 bar is permitted. To guarantee cooling capacity, depending on working cycle apressure differential of q3 bar between the cooling water inlet and cooling water outlet is required. Inlet distribution : On entry the cooling water is distributed via 3 res. 5(6) solenoid valves to 3 res. 5(6) circuits .... Hydraulic oil Fill zone in the screw cylinder Mould cooling Cooling of the heat exchanger converter cabinet. Cooling of the el. drive for injection unit Cooling gear box for the el. drive for injection unit (from EE 7000) Note: On machines with “WA 139 Separate water connections for mould cooling machine oil cooling”, however, the mould cooling is connected separately.
2-42
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Commissioning and Disassembly
2
Notes for Connecting the Cooling Water Supply – continuation Note:
Electrical screw drive with water–cooled electric motor Bei Maschinen mit “WA 138 Kühlwasseranschluß für Werkzeug– und Ölkühlung gemeinsam” darf die Zulauftemperatur 15C aufgrund der möglichen Betauung der Maschinenkühlung nicht unterschreiten. On machines with “WA 139 Separate water connections for mould cooling machine oil cooling”, however, the mould cooling is connected separately. Für die Maschinenkühlung darf eine Zulauftemperatur von 15C ebenfalls nicht unterschritten werden.
Attention! If there is no antifreeze in the cooling water, it is essential that the cooling water is drained out to prevent the cooling circuits from freezing up. Each cooling circuit should be blown out with compressed air. Before blowing out water–cooled electric motors fitted with a water drain plug, this must also be removed. (see separate operating manual from the electric motor manufacturer).
BA027.01.1.en
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Commissioning and Disassembly
2.7.3
Water Cooling System – Diagram
2.7.3.1
Water Cooling System – Diagram Standard
. " 4 41 41 ZE ZE
) 2) . " 41 43 41
c b f 2DV20
m a
. " 41 43 41 ZE
–4M1 W1
M
W2 & /0
1WT1
g
b m ZE 2AS38
2MA20
2SH22
2DM20
1DV24
4AS23 4SH60 1SH24 1AS22.1
1AS22.2 1S30
Picture 9: Water Cooling System – Diagram
1AS22.1 1AS22.2 2AS38 4AS23 1DV24 –1S30 –1S30 1SH24 1WT1 2DM20 2DV20 2MA20 –4M1 2SH22 4SH60 a b c f g m W1 W2
2-44
Directional Control Valve – el. drive screw Directional Control Valve – heat exchanger converter el. drive screw – cabinet Shut–off valve – air blast device for mould cooling circuits Directional Control Valve – cooling gear box for electrical screw drive Throttle Valve – oil cooler Flow detector Flow detector Directional control valve – Hydraulic oil cooling Hydraulic oil cooling system Pressure relief valve – Mould cooling Throttle valves – Mould cooling Manometer – Cooling Water Pressure Screw drive Directional Control Valve – Mould Cooling Directional Control Valve – Feed zone cooling Thermocouple – Feed Zone Floats – Mould cooling/or indication of flow rate in the feed zone Flow meters for flow rate Thermometers – Mould Cooling Shut–off valves – Mould Cooling High speed couplings – cooling water Heat exchanger converter cabinet Heat exchanger gear box for electrical screw drive
BA027.01.1.en
Commissioning and Disassembly
2.7.3.2
2
Water Cooling System – Diagram, on machines with separate watercooling circuits (ZE) ) 2) . " 41 43 41
. " 4 41 41 ZE ZE c b f 2DV20
m a
. " 41 43 41 ZE
–4M1 W1
M
W2 & /0
1WT1
g
b m 2MA20 ZE 2AS38
2SH22
2DM20
1DV24
4AS23 4SH60 1SH24 1AS22.1
1AS22.2 1S30
Picture 10: Water Cooling System – Diagram
1AS22.1 1AS22.2 2AS38 4AS23 1DV24 –1S30 1SH24 1WT1 2DM20 2DV20 2MA20 –4M1 2SH22 4SH60 a b c f g m W1 W2
BA027.01.1.en
Directional Control Valve – el. drive screw Directional Control Valve – heat exchanger converter el. drive screw – cabinet Shut–off valve – air blast device for mould cooling circuits Directional Control Valve – cooling gear box for electrical screw drive Throttle Valve – oil cooler Flow detector Directional control valve – Hydraulic oil cooling Hydraulic oil cooling system Pressure relief valve – Mould cooling Throttle valves – Mould cooling Manometer – Cooling Water Pressure Screw drive Directional Control Valve – Mould Cooling Directional Control Valve – Feed zone cooling Thermocouple – Feed Zone Floats – Mould cooling/or indication of flow rate in the feed zone Flow meters for flow rate Thermometers – Mould Cooling Shut–off valves – Mould Cooling High speed couplings – cooling water Heat exchanger converter cabinet Heat exchanger gear box for electrical screw drive
2-45
2
2.7.4
Commissioning and Disassembly
Hydraulic oil cooling system The water inlet is opened and closed via solenoid valve 1SH24 in order to regulate the oil temperature at a constant set value (40C ... 50C). Note: The set value should be set to the highest possible value in order to achieve the least cooling water consumption. Water throughput to oil cooler 1WT1 is set using the adjacent throttle valve 1DV24. To reduce cooling water consumption set throttle valve 1DV24 so that directional control valve 1SH24 is not actuated too often. Setting–Up– Operating: Indication is given on the ”Temperatures” screen page, chap. 4.5.6 of the set value (40C ... 50C), the... + and – Tolerances, and the... Actual value of the oil temperature.
2-46
BA027.01.1.en
Commissioning and Disassembly
2.7.5
2
Cooling the screw cylinder feed zone Directional control valve 4SH60 and FZ thermocouple control the supply of water for cooling the feed zone. A flow indicator at the cooling water inlet keeps a check on this function. Setting–up – Operating Screen page ”Temperatures”, chap. 4.5.6 is used to set the.... Set Temperature, and the... + and – Tolerances. The Actual Temperature is visible. Connection: Inlet and outlet to be attached to cooling flange with hose DN 10 and quick coupling.
BA027.01.1.en
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Commissioning and Disassembly
2.7.6
Cooling water consumption for hydraulic oil cooling system
2.7.6.1
Cooling water consumption (l/h) for machines capacity oil cooler Standard
2.7.6.1.1 Cooling water consumption (l/h) for machines capacity oil cooler Standard – Demag modular 125/475 up to 350/810 and 420/810 Machine Type
Pump capacity 22 kW
Demag modular 125/475
30 kW 22 kW
Demag modular 150/475
30 kW 22 kW
Demag modular 150/500
30 kW 22 kW
Demag modular 200/500
30 kW 30 kW
Demag modular 200/560
37 kW 30 kW
Demag modular 250/560
37 kW 37 kW
Demag modular 250/630
45 kW 37 kW
Demag modular 300/630
45 kW 45 kW
Demag modular 350/710
Demag modular 350/810
Demag modular 420/810 Table 10: Cooling water consumption.
2-48
55 kW 45 kW 55 kW 75 kW 45 kW 55 kW 75 kW
Water inlet temperature 15 _C 380 ( 35 ) 500 ( 36 ) 380 ( 35 ) 500 ( 36 ) 380 ( 35 ) 500 ( 36 ) 380 ( 35) 500 ( 36 ) 500 ( 36 ) 550 ( 38 ) 500 ( 36 ) 550 ( 38 ) 550 ( 38 ) 650 ( 39 ) 550 ( 38 ) 650 ( 39 ) 650 ( 39 ) 800 ( 39 ) 650 ( 39 ) 800 ( 39 ) 1100 ( 39 ) 650 ( 39 ) 800 ( 39 ) 1100 ( 39 )
20 _C 500 ( 35) 650 ( 36 ) 500 ( 35 ) 650 ( 36 ) 500 ( 35) 650 ( 36 ) 500 ( 35 ) 650 ( 36 ) 650 ( 36 ) 700 ( 38 ) 650 ( 36 ) 700 ( 38 ) 700 ( 38 ) 800 ( 39 ) 700 ( 38 ) 800 ( 39 ) 800 ( 39 ) 1000 ( 39 ) 800 ( 39 ) 1000 ( 39 ) 1350 ( 39 ) 800 ( 39 ) 1000 ( 39 ) 1350 ( 39 )
25 _C 750 ( 35 ) 900 ( 36 ) 750 ( 35 ) 900 ( 36 ) 750 ( 35 ) 900 ( 36 ) 750 ( 35 ) 900 ( 36 ) 900 ( 36 ) 950 ( 38 ) 900 ( 36 ) 950 ( 38 ) 950 ( 38 ) 1100 ( 39 ) 950 ( 38 ) 1100 ( 39 ) 1100 ( 39 ) 1400 ( 39 ) 1100 ( 39) 1400 ( 39 ) 1900 ( 39 ) 1100 ( 39) 1400 ( 39 ) 1900 ( 39 )
( ... ) = Water outlet temperature in C.
BA027.01.1.en
Commissioning and Disassembly
2
2.7.6.1.2 Cooling water consumption (l/h) for machines capacity oil cooler Standard – Demag modular 420/800 and 500/900 up to 2000/1800 Machine Type
Pump capacity
45 kW 55 kW Demag modular 420/800
75 kW 90 kW 45 kW 55 kW
Demag modular 500/900
75 kW 90 kW 75 kW
Demag modular 650/1000
90 kW 110 kW 75 kW
Demag modular 800/1120
90 kW 110 kW 75 kW 90 kW
Demag modular 1000/1400
110 kW 165 kW 110 kW
Demag modular 1300/1500 Demag modular 1500/1500 Demag modular 2000/1800 Table 11: Cooling water consumption.
BA027.01.1.en
165 kW 110 kW 165 kW 165 kW
Water inlet temperature 15 _C
20 _C
25 _C
600 ( 41 ) 750 ( 40 ) 1100 ( 35 ) 1200 ( 38 ) 600 ( 41 ) 750 ( 40 ) 1100 ( 35 ) 1200 ( 38 ) 1100 ( 35 ) 1200 ( 38 ) 1700 ( 35 ) 1100 ( 35 ) 1200 ( 38 ) 1700 ( 35 ) 1100 ( 35 ) 1200 ( 38 ) 1700 ( 35 ) 2800 ( 35 ) 1700 ( 35 ) 2800 ( 35 ) 1700 ( 35 ) 2800 ( 35 ) 2800 ( 35 )
750 ( 41 ) 950 ( 40 ) 1500 ( 35 ) 1600 ( 38 ) 750 ( 41 )
1000 ( 40 ) 1300 ( 40 ) 2200 ( 35 ) 2300 ( 37 ) 1000 ( 40 ) 1300 ( 40 ) 2200 ( 35 ) 2300 ( 37 ) 2200 ( 35 ) 2300 ( 37 ) 4000 ( 35 ) 2200 ( 35 ) 2300 ( 37 ) 4000 ( 35 ) 2200 ( 35 ) 2300 ( 37 ) 4000 ( 35 ) 6500 ( 33 ) 4000 ( 35 ) 6500 ( 33 ) 4000 ( 35 ) 6500 ( 33 ) 6500 ( 33 )
950 ( 40 ) 1500 ( 35 ) 1600 ( 38 ) 1500 ( 35 ) 1600 ( 38 ) 2400 ( 35 ) 1500 ( 35 ) 1600 ( 38 ) 2400 ( 35 ) 1500 ( 35 ) 1600 ( 38 ) 2400 ( 35 ) 4000 ( 34 ) 2400 ( 35 ) 4000 ( 34 ) 2400 ( 35 ) 4000 ( 34 ) 4000 ( 34 )
( ... ) = Water outlet temperature in C
2-49
2
Commissioning and Disassembly
2.7.6.2
Cooling water consumption (l/h) for machines ZE...high capacity oil cooler 2.7.6.2.1 Cooling water consumption (l/h) for machines ZE...high capacity oil cooler – Demag modular 125/475 up to 350/710 and 420/810 Machine Type
Pump capacity 22 kW
Demag modular 125/475
30 kW 22 kW
Demag modular 150/475
30 kW 22 kW
Demag modular 150/500
30 kW 22 kW
Demag modular 200/500
30 kW 30 kW
Demag modular 200/560
37 kW 30 kW
Demag modular 250/560
37 kW 37 kW
Demag modular 250/630 Demag modular 300/630 Demag modular 350/710 Demag modular 350/810
Demag modular 420/810 Table 12: Cooling water consumption.
2-50
45 kW 37 kW 45 kW 45 kW 55 kW 45 kW 55 kW 75 kW 45 kW 55 kW 75 kW
Water inlet temperature 15 _C 20 _C 300 380 ( 40 ) ( 40 ) 400 500 ( 41 ) ( 41 ) 300 380 ( 40 ) ( 40 ) 400 500 ( 41 )4 ( 41 ) 300 380 ( 40 ) ( 40 ) 400 500 ( 41 ) ( 41 ) 300 380 ( 40 ) ( 40 ) 400 500 ( 41 ) ( 41 ) 400 500 ( 41 ) ( 41 ) 500 600 ( 40 ) ( 41 ) 400 500 ( 41 ) ( 41 ) 500 600 ( 40 ) ( 41 ) 500 600 ( 40 ) ( 41 ) 600 750 ( 41) ( 41 ) 500 ( 40 ) 600 ( 41 ) 600 ( 41 ) 750 ( 41 ) 600 ( 41 ) 750 ( 41 ) 750 ( 40 ) 950 ( 40 ) 600 ( 41 ) 750 ( 41 ) 750 ( 40 ) 950 ( 40 ) 1000 ( 40 ) 1300 ( 40 ) 600 ( 41 ) 750 ( 41 ) 750 ( 40 ) 950 ( 40 ) 1000 ( 40 ) 1300 ( 40 )
25 _C 500 ( 40 ) 650 ( 41 ) 500 ( 40 ) 650 ( 41 ) 500 ( 40 ) 650 ( 41 ) 500 ( 40 ) 650 ( 41 ) 650 ( 41 ) 800 ( 41 ) 650 ( 41 ) 800 ( 41 ) 800 ( 41 ) 950 ( 41 ) 800 ( 41 ) 950 ( 41 ) 950 ( 41 ) 1200 ( 41 ) 950 ( 41 ) 1200 ( 41 ) 1650 ( 41 ) 950 ( 41 ) 1200 ( 41 ) 1650 ( 41 )
30 _C 750 ( 40 ) 900 ( 41 ) 750 ( 40 ) 900 ( 41 ) 750 ( 40 ) 900 ( 41 ) 750 ( 40 ) 900 ( 41 ) 900 ( 41 ) 1200 ( 41 ) 900 ( 41 ) 1200 ( 41 ) 1200 ( 41 ) 1450 ( 41 ) 1200 ( 41 ) 1450 ( 41 ) 1450 ( 41 ) 1800 ( 41 ) 1450 ( 41 ) 1800 ( 41 ) 2500 ( 41 ) 1450 ( 41 ) 1800 ( 41 ) 2500 ( 41 )
( ... ) = Water outlet temperature in C.
BA027.01.1.en
Commissioning and Disassembly
2
2.7.6.2.2 Cooling water consumption (l/h) for machines ZE...high capacity oil cooler – Demag modular 420/800 and 500/900 up to 2000/1800 Machine Type
Pump capacity
45 kW 55 kW Demag modular 420/800
75 kW 90 kW 45 kW 55 kW
Demag modular 500/900
75 kW 90 kW 75 kW
Demag modular 650/1000
90 kW 110 kW 75 kW
Demag modular 800/1120
90 kW 110 kW 75 kW 90 kW
Demag modular 1000/1400
110 kW 165 kW 110 kW
Demag modular 1300/1500 Demag modular 1500/1500 Demag modular 2000/1800 Table 13: Cooling water consumption.
BA027.01.1.en
165 kW 110 kW 165 kW 165 kW
Water inlet temperature 15 _C 20 _C 25 _C 30 _C 580 700 900 1300 ( 42 ) ( 42 ) ( 42 ) ( 42 ) 750 900 1150 1700 ( 40 ) ( 41 ) ( 41 ) ( 41 ) 900 1100 1500 2200 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1100 1400 1900 2600 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 580 700 900 1300 ( 42 ) ( 42 ) ( 42 ) ( 42 ) 750 900 1150 1700 ( 40 ) ( 41 ) ( 41 ) ( 41 ) 900 1100 1500 2200 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1100 1400 1900 2600 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 900 1100 1500 2200 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1100 1400 1900 2600 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1500 1800 2500 4200 ( 38 ) ( 38 ) ( 38 ) ( 38 ) 900 1100 1500 2200 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1100 1400 1900 2600 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1500 1800 2500 4200 ( 38 ) ( 38 ) ( 38 ) ( 38 ) 900 1100 1500 2200 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1100 1400 1900 2600 ( 40 ) ( 40 ) ( 40 ) ( 40 ) 1500 1800 2500 4200 ( 38 ) ( 38 ) ( 38 ) ( 38 ) 2400 3000 4200 7500 ( 38 ) ( 38 ) ( 38 ) ( 38 ) 1500 1800 2500 4200 ( 38 ) ( 38 ) ( 38 ) ( 38 ) 2400 3000 4200 7500 ( 38 ) ( 38 ) ( 38 ) ( 38 ) 1500 ( 38 ) 1800 ( 38 ) 2500 ( 38 ) 4200 ( 38 ) 2400 ( 38 ) 3000 ( 38 ) 4200 ( 38 ) 7500 ( 38 ) 2400 ( 38 ) 3000 ( 38 ) 4200 ( 38 ) 7500 ( 38 ) ( ... ) = Water outlet temperature in C.
2-51
2
2.7.7
Commissioning and Disassembly
Mould Cooling 6
5
4
3
2
1
c
b w
f g 2DV20
) 2) . " + 41 43 41
Ø 12 (3/8”)
Picture 11: Cooling water flow controller
2 DV 20 b c f g w
Throttle valves Floats for indicating flow rate Flow meters Thermometers to indicate return temperature from the mould Shut–off valves for cooling circuits which are not required Marker rings to aid setting of flow rate
Note: Demag modular 125/475 up to 350/810 and 420/810: Demag modular 420/800 and 500/900 up to 2000/1800:
4 Circuits
6 Circuits
Use – Application Following injection, the mould is cooled in the mould until the mould opens. The flow regulator enables an accurate flow setting to be made with temperature control for each mould cooling circuit.
2-52
BA027.01.1.en
Commissioning and Disassembly
2
Mould Cooling – Continued Setting Setting the flow rate on throttle valve 2DV20. Indication of cooling water flow rate – return flow from mould. Using marker rings w on flow meters c with floats b. The floats b are normally made of brass. Floats are also available in aluminium or PVC for use with mould with minimum flow rates. Temperature indication of the return flow from the mould with thermometers f. There are 4 (Demag modular 125/475 up to 350/810 and 420/810) res. 6 (Demag modular 420/800 and 500/900 up to 2000/1800)cooling circuits available. These can be extended to 8 res. 12 circuits (Demag modular 125/475 up to 350/810 and 420/810) resp. 10 circuits (Demag modular 420/800 and 500/900 up to 2000/1800) with ZE... Function Feed via directional control valve 2SH22. During the setting –up operation mould cooling is switched on. During Manual– operationit is switched off. For Semi–automatic – and automatic operationmould cooling is switched on at the start of the machine cycle. When there are operating faults which do not lead to a total shut–down of the machine, the mould continues to its basic position and mould cooling is switched off after a delay. This enables the operating temperature in the mould to be retained for longer period.
This delay time is set on the ”Mould” page chap. 4.5.1
Connection: Connection of mould cooling circuits to cooling water flow control unit on 12 mm socket. for 3/8” or 1/2” hose. The hoses for connecting the cooling water flow control unit to the mould do not belong to our product range.
BA027.01.1.en
2-53
2
2.8
Commissioning and Disassembly
Filling with Hydraulic Oil
a
a
( #' )$+
, )*# $' )*#
( $' )* ) ' )#*
Picture 12: Oil feed opening
The tank ventilation filter also serves as a seal for oil feed opening a. Note: Fresh hydraulic oil is often insufficiently filtered for machine operation. We recommend filling the oil through a filter device with a downstream fine filtration unit (10 µm). Remove the cap and filter element. Use a hydraulic oil in accordance with the lubricant table in chap. 6.2.
2-54
BA027.01.1.en
Commissioning and Disassembly
2.8.1
2
Hydraulic Oil – tank capacities
Machine Type
Oil filling [ltr.]
Demag modular 125/475
400
Demag modular 150/475
400
Demag modular 150/500
400
Demag modular 200/500
400
Demag modular 200/560
500
Demag modular 250/560
500
Demag modular 250/630
700
Demag modular 300/630
700
Demag modular 350/710
700
Demag modular 350/810
730
Demag modular 420/810
730
Demag modular 420/800
760
Demag modular 500/900
Demag modular 650/1000
MB I
EE 2300
760
EE 3300
7600
MB II
EE 6400
1300
MB I
EE 3300 I 75 kW
760
MB II
EE 3300 II 90 kW
1300
EE 6400
1300
EE 9500
1300
Demag modular 800/1120
MB II
1300
Demag modular 1000/1400–5200
MB II
1300
Demag modular 1000/1400–8000
MB II
1300
Demag modular 1000/1400–11500
MB III
2000
Demag modular 1000/1400–16000
MB III
2000
Demag modular 1300/1500–8000
MB II
1300
Demag modular 1300/1500–11500
MB III
2000
Demag modular 1300/1500–16000
MB III
2000
Demag modular 1500/1500
MB III
2000
Demag modular 2000/1800
MB III
2000
Table 14: Tank capacities
BA027.01.1.en
2-55
2
Commissioning and Disassembly
2.9
Electrical Connection
2.9.1
Notes on electrical connection – clamping unit / injection unit – Demag modular 420/800 and 500/900 up to 2000/1800 The connecting cables from the clamping unit to the injection unit are seperated for transport and must be connected after installation. All electric leads are provided with multiple plugs which coinside with the correspondingly marked mulitple sockets. Exceptions:
Cabel for hotrunners are directly fitted in the power cabinet. Cabel for thermocouples of control zone –MH5 and – MH6 are directly fitted in the electrical distribution box –X19.
Plug– / cable designation
Point of departure
Connecting position
Remark
–X1 ..... –X7
Clamping unit
control cabinet
Piug with screws (each 2x M3x8) to safe
–1X7, –1X11
control cabinet
Ergocontrol – back side
–2X14
Clamping unit
non–operater side proximity disconnecting point clamping–/injection unit
–W18
Electrical distribution box –X13 (screw cylinder)
Electrical distribution box – X19 (clamping unit non–operater side)
only IU 3300, IU 6400, IU 9500, IU 11500 and IU 16000
–W28.1 , –W28.2
Electrical distribution box –X19 (clamping unit non–operater side)
Power cabinet lay –6K26.1, –6K26.2
Cabling see circuit diagramm
PE
Re-
non–operater side disconnecting point clamping–/injection unit
Eart connection
Attention! Connection of the power supply should only be undertaken by an qualified electrician.
2-56
BA027.01.1.en
Commissioning and Disassembly
2.9.2
2
Notes on electrical connection – power supply
–1Q0
Main ON–OFF switch
The electrical equipment on the machine is in accordance with specific customer requirements. Normally, the injection moulding machine is equipped for 3 phase current, 400 volt with Neutral and Earth conductors and a frequency of 50 Hz. Attention! Connection of the power supply should only be undertaken by an qualified electrician. The rules and regulations of the power supply company concerned must be adhered to. The power supply is connected on Main Switch –1QO in the control cabinet. See appendix for circuit diagram – Power. For position on the machine see Installation Plans chap. 2.3. Attention! Even with the heating switched off or isolated there is still full voltage to earth on cartridge heaters, heater bands, plugs, terminals etc. Main switch –1Q0 must always be switched off when work is being carried out on the heating system.
BA027.01.1.en
2-57
2
2.9.3
Commissioning and Disassembly
Check direction of rotation of pump motor
–1S31
Pump motor ON–OFF
When the power has been connected, the direction of rotation of pump motor –1M1 must be checked again. Note: Having connected the machine up and switched on, check in the switch cabinet that the pump amplifier (–1N7) is functioning correctly – (green LED must light up). If red LED is on, check that the card is located properly. Note: The hydraulic oil must be topped up ! Switch on Main Switch –1QO. Briefly start up pump motor –1M1 using switch –1S31. Check whether the direction of rotation tallies with the direction of the arrow on the motor housing. If the direction of rotation is incorrect, power leads L1 and L2 must be swapped over. Note: If the pump motor is caused to rotate in the wrong direction, the hydraulic pumps can be damaged.
2-58
BA027.01.1.en
Commissioning and Disassembly
2.9.4 2.9.4.1
2
Electrical installation data Electrical installation data Demag modular 125/475 and 150/475
Model description Supply I motors
Supply II heating
Pump unit
WA 313 Electrical screw drive ZE 161 Integr. socket combination ZE 751 Integr. handling device ZE 770 Temperat. control unit Screw cylinder 20 D 20 D 20 D 25 D ZE 266 1 hot runner zone ZE 267 2 hot runner zones ZE 268 3 hot runner zones ZE 269 5 hot runner zones ZE 277 7 hot runner zones ZE 271 8 hot runner zones ZE 279 9 hot runner zones ZE 278 12 hot runner zones ZE 272 16 hot runner zones ZE 510 Additionally nozzle heater band ZE 532 1 additional controllers
Fuse protection Electrical connection
BA027.01.1.en
125/475–320 150/475–320 22 kW 41 A
125/475–440 150/475–440 22 kW 41 A
125/475–610 150/475–610 22 kW 41 A
30 kW 55 A
30 kW 55 A 30 kW 55 A
30 kW 55 A 30 kW 55 A
12,6 kW 28 A
12,6 kW 28 A
18,6 kW 40 A
24 kW 35 A __ kW __ A 13 kW 19 A 7,9 kW 11 A
8,3 kW 12 A
11,7 kW 17 A
8,3 kW 12 A 11,7 kW 17 A 13,0 kW 18 A 11,7 kW 17 A 13,0 kW 18 A 14,8 kW 21 A 13,9 kW 20 A 15,7 kW 23 A 2,7 kW 12 A 5,5 kW 12 A 8,2 kW 12 A 13,7 kW 23 A 19,2 kW 35 A 22 kW 35 A 24,7 kW 35 A 33 kW 47 A 44 kW 63 A 1 kW
4A
1 kW
4A
Add respective nominal ratings and rated currents 400 V, 3/N/50 Hz 5
2-59
2
2.9.4.2
Commissioning and Disassembly
Electrical installation data Demag modular 150/500 and 200/500
Model description Supply I motors
Supply II heating
Pump unit
150/500–440 200/500–440 22 kW 41 A
150/500–610 200/500–610 22 kW 41 A
150/500–840 200/500–840 22 kW 41 A
30 kW 55 A
30 kW 55 A 37 kW 67 A
30 kW 55 A 37 kW 67 A
WA 313 Electrical screw drive ZE 161 Integr. socket combination ZE 751 Integr. handling device ZE 770 Temperat. control unit Screw cylinder 20 D
12,6 kW 28 A 18,6 kW 40 A 20,5 kW 44 A
20 D 20 D 25 D
11,7 kW 17 A 13,0 kW 18 A 14,8 kW 21 A 13,0 kW 18 A 14,8 kW 21 A 23,1 kW 33 A 15,7 kW 23 A 18,3 kW 26 A
ZE 266 1 hot runner zone ZE 267 2 hot runner zones ZE 268 3 hot runner zones ZE 269 5 hot runner zones ZE 277 7 hot runner zones ZE 271 8 hot runner zones ZE 279 9 hot runner zones ZE 278 12 hot runner zones ZE 272 16 hot runner zones ZE 510 Additionally nozzle heater band ZE 532 1 additional controllers Fuse protection Electrical connection
24 kW 35 A __ kW __ A 13 kW 19 A 8,3 kW 12 A
11,7 kW 17 A 13,0 kW 18 A
2,7 kW 12 A 5,5 kW 12 A 8,2 kW 12 A 13,7 kW 23 A 19,2 kW 35 A 22 kW 35 A 24,7 kW 35 A 33 kW 47 A 44 kW 63 A 1 kW
4A
1 kW
4A
Add respective nominal ratings and rated currents 400 V, 3/N/50 Hz 5
2-60
BA027.01.1.en
Commissioning and Disassembly
2.9.4.3
2
Electrical installation data Demag modular 200/560 and 250/560
Model description Supply I motors
Pump unit
200/560–610 250/560–610 30 kW 55 A 37 kW 67 A
200/560–840 250/560–840 30 kW 55 A 37 kW 67 A 45 kW 84 A
200/560 – 1450 250/560 – 1450 30 kW 55 A 37 kW 67 A 45 kW 84 A
WA 313 18,6 kW 40 A 20,5 kW 44 A 30 kW 60 A Electrical screw drive ZE 161 24 kW 35 A Integr. socket combination ZE 751 __ kW __ A Integr. handling device ZE 770 13 kW 19 A Temperat. control unit Supply II Screw cylinder 20 D 11,7 kW 17 A 13,0 kW 18 A 14,8 kW 21 A heating 20 D 13,0 kW 18 A 14,8 kW 21 A 23,1 kW 33 A 20 D 14,8 kW 21 A 23,1 kW 33 A 27,0 kW 39 A 25 D 18,3 kW 26 A 27,9kW 40 A ZE 266 2,7 kW 12 A 1 hot runner zone ZE 267 5,5 kW 12 A 2 hot runner zones ZE 268 8,2 kW 12 A 3 hot runner zones ZE 269 13,7 kW 23 A 5 hot runner zones ZE 277 19,2 kW 35 A 7 hot runner zones ZE 271 22 kW 35 A 8 hot runner zones ZE 279 24,7 kW 35 A 9 hot runner zones ZE 278 33 kW 47 A 12 hot runner zones ZE 272 44 kW 63 A 16 hot runner zones ZE 510 1 kW 4 A Additionally nozzle heater band ZE 532 1 kW 4 A 1 additional controllers Fuse protection Add respective nominal ratings and rated currents Electrical connection 400 V, 3/N/50 Hz 5
BA027.01.1.en
2-61
2
2.9.4.4
Commissioning and Disassembly
Electrical installation data Demag modular 250/630 and 300/630
Model description Supply I motors
Supply II heating
Pump unit
WA 313 Electrical screw drive ZE 161 Integr. socket combination ZE 751 Integr. handling device ZE 770 Temperat. control unit Screw cylinder 20 D 20 D 20 D 25 D ZE 266 1 hot runner zone ZE 267 2 hot runner zones ZE 268 3 hot runner zones ZE 269 5 hot runner zones ZE 277 7 hot runner zones ZE 271 8 hot runner zones ZE 279 9 hot runner zones ZE 278 12 hot runner zones ZE 272 16 hot runner zones ZE 510 Additionally nozzle heater band ZE 532 1 additional controllers
Fuse protection Electrical connection
2-62
250/630–840 300/630–840 37 kW 67 A 45 kW 84 A
250/630–1450 300/630–1450 37 kW 67 A 45 kW 84 A 55 kW 97 A
250/630–2300 300/630–2300 37 kW 67 A 45 kW 84 A 55 kW 97 A
20,5 kW 44 A
30 kW 60 A
36 kW 70 A
24 kW 35 A __ kW __ A 13 kW 19 A 13,0 kW 18 A 14,8 kW 14,8 kW 21 A 23,1 kW 23,1 kW 33 A 27,0 kW 27,9 kW
21 A 23,1 kW 33 A 33 A 27,0 kW 39 A 39 A 30,6 kW 44 A 40 A 32,2 kW 46 A
2,7 kW 12 A 5,5 kW 12 A 8,2 kW 12 A 13,7 kW 23 A 19,2 kW 35 A 22 kW 35 A 24,7 kW 35 A 33 kW 47 A 44 kW 63 A 1 kW
4A
1 kW
4A
Add respective nominal ratings and rated currents 400 V, 3/N/50 Hz 5
BA027.01.1.en
Commissioning and Disassembly
2.9.4.5
2
Electrical installation data Demag modular 350/710
Model description Supply I Pump unit motors
Supply II heating
WA 313 Electrical screw drive ZE 161 Integr. socket combination ZE 751 Integr. handling device ZE 770 Temperat. control unit Screw cylinder 20 D 20 D 20 D 25 D ZE 266 1 hot runner zone ZE 267 2 hot runner zones ZE 268 3 hot runner zones ZE 269 5 hot runner zones ZE 277 7 hot runner zones ZE 271 8 hot runner zones ZE 279 9 hot runner zones ZE 278 12 hot runner zones ZE 272 16 hot runner zones ZE 510 Additionally nozzle heater band ZE 532 1 additional controllers
Fuse protection Electrical connection
BA027.01.1.en
350/710–840
350/710–1450
350/710–2300
45 kW 84 A
45 kW 84 A
45 kW 84 A
55 kW 97 A
55 kW 97 A 55 kW 97 A
55 kW 97 A 75 kW 134 A
20,5 kW 44 A
30 kW 60 A
36 kW
70 A
24 kW 35 A __ kW __ A 13 kW 19 A 13,0 kW 18 A
14,8 kW 21 A
23,1 kW 33 A
14,8 kW 21 A 23,1 kW 33 A 27,0 kW 39 A 23,1 kW 33 A 27,0 kW 39 A 30,6 kW 44 A 27,9kW 40 A 32,2 kW 46 A 2,7 kW 12 A 5,5 kW 12 A 8,2 kW 12 A 13,7 kW 23 A 19,2 kW 35 A 22 kW 35 A 24,7 kW 35 A 33 kW 47 A 44 kW 63 A 1 kW
4A
1 kW
4A
Add respective nominal ratings and rated currents 400 V, 3/N/50 Hz 5
2-63
2
2.9.4.6
Commissioning and Disassembly
Electrical installation data Demag modular 350/810
Model description Supply I Pump unit motors
350/810–1450 45 kW 84 A 55 kW 97 A
350/810 – 2300 45 kW 84 A 55 kW 97 A
350/810 – 3300 55 kW 97 A 75 kW 134 A
WA 313 30 kW 60 A 36 kW 70 A 40 kW 78 A Electrical screw drive ZE 161 24 kW 35 A Integr. socket combination ZE 751 __ kW __ A Integr. handling device Supply II Screw cylinder Ø 50 14,8 kW 21 A heating Ø 60 23,1 kW 33 A 23,1 kW 33 A Supply II Ø 70 27,0 kW 39 A 27,0 kW 39 A 30.6 kW 44 A heating Ø 80 30,6 kW 44 A 30.6 kW 44 A Ø 95 42.6 kW 66 A Ø 60 27,9 kW 40 A Ø 70 32,2 kW 46 A Ø 80 42,5 kW 61 A ZE 266 2,7 kW 12 A 1 hot runner zone ZE 267 5,5 kW 12 A 2 hot runner zones ZE 268 8,2 kW 12 A 3 hot runner zones ZE 269 13,7 kW 23 A 5 hot runner zones ZE 277 19,2 kW 35 A 7 hot runner zones ZE 279 24,7 kW 35 A 9 hot runner zones ZE 278 33 kW 47 A 12 hot runner zones ZE 272 44 kW 63 A 16 hot runner zones ZE 510 1 kW 4 A Additionally nozzle heater band ZE 532 1 kW 4 A 1 additional controllers Fuse protection Add respective nominal ratings and rated currents Electrical connection 2x 400 V, 3/N/50 Hz 5
2-64
BA027.01.1.en
Commissioning and Disassembly
2.9.4.7
2
Electrical installation data Demag modular 420/810
Model description Supply I Pump unit motors
420/810–1450 45 kW 84 A 55 kW 97 A
420/810 – 2300 45 kW 84 A 55 kW 97 A
420/810 – 3300 55 kW 97 A 75 kW 134 A
WA 313 30 kW 60 A 36 kW 70 A 40 kW 78 A Electrical screw drive ZE 161 24 kW 35 A Integr. socket combination ZE 751 __ kW __ A Integr. handling device Supply II Screw cylinder Ø 50 14,8 kW 21 A heating Ø 60 23,1 kW 33 A 23,1 kW 33 A Supply II Ø 70 27,0 kW 39 A 27,0 kW 39 A 30.6 kW 44 A heating Ø 80 30,6 kW 44 A 30.6 kW 44 A Ø 95 42.6 kW 66 A Ø 60 27,9 kW 40 A Ø 70 32,2 kW 46 A Ø 80 42,5 kW 61 A ZE 266 2,7 kW 12 A 1 hot runner zone ZE 267 5,5 kW 12 A 2 hot runner zones ZE 268 8,2 kW 12 A 3 hot runner zones ZE 269 13,7 kW 23 A 5 hot runner zones ZE 277 19,2 kW 35 A 7 hot runner zones ZE 279 24,7 kW 35 A 9 hot runner zones ZE 278 33 kW 47 A 12 hot runner zones ZE 272 44 kW 63 A 16 hot runner zones ZE 510 1 kW 4 A Additionally nozzle heater band ZE 532 1 kW 4 A 1 additional controllers Fuse protection Add respective nominal ratings and rated currents Electrical connection 2x 400 V, 3/N/50 Hz 5
BA027.01.1.en
2-65
2
2.9.4.8
Commissioning and Disassembly
Electrical installation data Demag modular 420/800
Model description Supply I Pump unit motors
420/800–1450 45 kW 84 A 55 kW 97 A
420/800 – 2300 45 kW 84 A 55 kW 97 A
420/800 – 3300 55 kW 97 A 75 kW 134 A
WA 313 38 kW 82 A 47 kW 107 A 53 kW 123 A Electrical screw drive ZE 161 24 kW 35 A Integr. socket combination ZE 751 __ kW __ A Integr. handling device Supply II Screw cylinder Ø 50 14,8 kW 21 A heating Ø 60 23,1 kW 33 A 23,1 kW 33 A Ø 70 27,0 kW 39 A 27,0 kW 39 A 30.6 kW 44 A Ø 80 30,6 kW 44 A 30.6 kW 44 A Ø 95 42.6 kW 66 A Ø 60 27,9 kW 40 A Ø 70 32,2 kW 46 A Ø 80 42,5 kW 61 A ZE 266 2,7 kW 12 A 1 hot runner zone ZE 267 5,5 kW 12 A 2 hot runner zones ZE 268 8,2 kW 12 A 3 hot runner zones ZE 269 13,7 kW 23 A 5 hot runner zones ZE 277 19,2 kW 35 A 7 hot runner zones ZE 279 24,7 kW 35 A 9 hot runner zones ZE 278 33 kW 47 A 12 hot runner zones ZE 272 44 kW 63 A 16 hot runner zones ZE 273 66 kW 104 A 24 hot runner zones ZE 274 88 kW 104 A 32 hot runner zones ZE 510 1 kW 4 A Additionally nozzle heater band ZE 532 1 kW 4 A 1 additional controllers Fuse protection Add respective nominal ratings and rated currents Electrical connection 2x 400 V, 3/N/50 Hz *) 5 *) also 2 electrical connections to by needed when only 1 net is available.
2-66
BA027.01.1.en
Commissioning and Disassembly
2.9.4.9
2
Electrical installation data Demag modular 500/900
Model description Supply I Pump unit motors
Supply II heating
WA 313 Electrical screw drive ZE 161 Integr. socket combination ZE 751 Integr. handling device Screw cylinder Ø 60 Ø 70 Ø 80 Ø 95 Ø 110 Ø 70 Ø 80 Ø 95 ZE 266 1 hot runner zone ZE 267 2 hot runner zones ZE 268 3 hot runner zones ZE 269 5 hot runner zones ZE 277 7 hot runner zones ZE 279 9 hot runner zones ZE 278 12 hot runner zones ZE 272 16 hot runner zones ZE 273 24 hot runner zones ZE 274 32 hot runner zones ZE 510 Additionally nozzle heater band ZE 532 1 additional controllers
Fuse protection Electrical connection *)
BA027.01.1.en
500/900–2300 45 kW 84 A 55 kW 97 A
47 kW 107 A
500/900–3300 55 kW 97 A 75 kW 134 A 53 kW 123 A
500/900–6400 75 kW 134 A 90 kW 168 A 90 kW 192 A
24 kW 35 A __ kW __ A 23,1 kW 33 A 27,0 kW 39 A 30,6 kW 44 A 32,2 kW 46 A
30.6 kW 44 A 30,6 kW 44 A 42.6 kW 66 A 42,5 kW 61 A
42.6 kW 66 A 42.6 kW 66 A 59.0 kW 95 A 59.0 kW 95 A
2,7 kW 12 A 5,5 kW 12 A 8,2 kW 12 A 13,7 kW 23 A 19,2 kW 35 A 24,7 kW 35 A 33 kW 47 A 44 kW 63 A 66 kW 104 A 88 kW 104 A 1 kW
4A
1 kW
4A
Add respective nominal ratings and rated currents 2x 400 V, 3/N/50 Hz *) 5 also 2 electrical connections to by needed when only 1 net is available.
2-67
2
2.9.4.10
Commissioning and Disassembly
Electrical installation data Demag modular 650/1000
Model description Supply I Pump unit motors
Supply II heating
WA 313 Electrical screw drive ZE 161 Integr. socket combination ZE 751 Integr. handling device Screw cylinder Ø 70 Ø 80 Ø 95 Ø 110 Ø 130 Ø 80 Ø 95 Ø 110 ZE 266 1 hot runner zone ZE 267 2 hot runner zones ZE 268 3 hot runner zones ZE 269 5 hot runner zones ZE 277 7 hot runner zones ZE 279 9 hot runner zones ZE 278 12 hot runner zones ZE 272 16 hot runner zones ZE 273 24 hot runner zones ZE 274 32 hot runner zones ZE 510 Additionally nozzle heater band ZE 532 1 additional controllers
Fuse protection Electrical connection *)
2-68
650/1000–3300 75 kW 134 A 90 kW 168 A
650/1000–6400 75 kW 134 A 90 kW 168 A
53 kW 123 A
90 kW 192 A
650/1000–9500 90 kW 168 A 110 kW 194 A 115 kW 245 A
24 kW 35 A __ kW __ A 30.6 kW 44 A 30.6 kW 44 A 42.6 kW 66 A 42,5 kW 61 A
42.6 kW 66 A 42.6 kW 66 A 59.0 kW 95 A 59.0 kW 95 A
59.0 kW 95 A 59.0 kW 95 A 79,0kW 115 A 79,0kW 115 A
2,7 kW 12 A 5,5 kW 12 A 8,2 kW 12 A 13,7 kW 23 A 19,2 kW 35 A 24,7 kW 35 A 33 kW 47 A 44 kW 63 A 66 kW 104 A 88 kW 104 A 1 kW
4A
1 kW
4A
Add respective nominal ratings and rated currents 2x 400 V, 3/N/50 Hz *) 5 also 2 electrical connections to by needed when only 1 net is available.
BA027.01.1.en
Commissioning and Disassembly
2.9.4.11
2
Electrical installation data Demag modular 800/1120
Model description Supply I Pump unit motors
800/1120–6400 75 kW 134 A 90 kW 168 A
800/1120–9500 90 kW 168 A 110 kW 194 A
WA 313 90 kW 192 A 115 kW 245 A Electrical screw drive ZE 161 24 kW 35 A Integr. socket combination ZE 751 __ kW __ A Integr. handling device Supply II Screw cylinder Ø 80 42.6 kW 66 A heating Ø 95 42.6 kW 66 A 59.0 kW 95 A Ø 110 59.0 kW 95 A 59.0 kW 95 A Ø 130 79,0kW 115 A Ø 95 59.0 kW 95 A Ø 110 79,0kW 115 A ZE 266 2,7 kW 12 A 1 hot runner zone ZE 267 5,5 kW 12 A 2 hot runner zones ZE 268 8,2 kW 12 A 3 hot runner zones ZE 269 13,7 kW 23 A 5 hot runner zones ZE 277 19,2 kW 35 A 7 hot runner zones ZE 279 24,7 kW 35 A 9 hot runner zones ZE 278 33 kW 47 A 12 hot runner zones ZE 272 44 kW 63 A 16 hot runner zones ZE 273 66 kW 104 A 24 hot runner zones ZE 274 88 kW 104 A 32 hot runner zones ZE 510 1 kW 4 A Additionally nozzle heater band ZE 532 1 kW 4 A 1 additional controllers Fuse protection Add respective nominal ratings and rated currents Electrical connection 2x 400 V, 3/N/50 Hz *) 5 *) also 2 electrical connections to by needed when only 1 net is available.
BA027.01.1.en
2-69
2
2.10
Commissioning and Disassembly
Dismantling Note: The dismantling of the machine should be done by Demag Plastics Group engineers or under supervision of a Demag service engineer. Prior to dismantling the machine the clamp and injection units should be moved to the position, where the transport protection can be installed. (see chap. 2.5.2). Disconnect the connections for cooling water and power supply prior to dismantling. (see chap. 2.7.1 and chap. 2.9.2) Attention! The disconnection of the power supply should only be carried out by an electrical engineer. Drain the cooling water completely. Each individual cooling circuit should be blown out with compressed air Empty the oil tank with the help of a pump via the oil feed opening. (see chap. 6.7.3). Note: Pollution control: The old oil must be properly disposed of. Return to oil supplier etc. Separate all hydraulic and electrical connections between clamp unit and injection unit (see chap. 2.5.3.2 and Kap. 2.9.1). Close all open hydraulic hoses with appropriate stopper. Separate the clamp and injection unit (see chap. 2.5.3.2). Take care to protect the unprotected parts such as piston rods, tie bars and mould mounting platen surfaces with a special anti–corrosion product.
2-70
BA027.01.1.en
Table of contents
3
3
Safety 3.1
General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3.1.1
Accident Prevention Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3.1.2
Maintenance and Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3.1.3
Toxic gases, fumes or dustes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3.1.4
Explosive decomposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3.1.5
Dangers from hot temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3.1.6
Noise level of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3.2
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
3.2.1
Arrangement of Safety Equipment Demag modular 125/475 to 350/810 and 420/810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of Safety Equipment Demag modular 420/800, 500/900 to 800/1120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of Safety Equipment Demag modular 1000/1400 up to 2000/1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1.1 3.2.1.2 3.2.2 3.2.2.1 3.2.2.2 3.2.2.3 3.2.2.4 3.2.2.5 3.2.2.6 3.2.2.7 3.2.2.8 3.2.2.9 3.2.2.10
3-6 3-7 3-8
Description of Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moveable guard in the mould area – operator side . . . . . . . . . . . . . . . . . . . . . Safety treadplate (from Demag modular 1000/1400) . . . . . . . . . . . . . . . . . . . . . Mechanical locking pawl (from Demag modular 1000/1400) . . . . . . . . . . . . . . Moveable Guard in the Mould Area – Non Operator Side . . . . . . . . . . . . . . . . Moveable Guard in the Nozzle Area – Operator Side . . . . . . . . . . . . . . . . . . . Moveable Guard in the Nozzle Area – Non Operator side . . . . . . . . . . . . . . . Moveable Guard – Plasticising Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Guard – Plasticising Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other hazards with the guards open in the nozzle area – Operator and Non–Operator side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9 3-9 3-11 3-11 3-11 3-12 3-12 3-13 3-13 3-13
3.3
Hydraulic Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
3.3.1
Accumulator System (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15
3.4
Electrical Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
3.4.1
VDE – Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
3.4.2
Earth Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
3.4.3
Emergency–Stop button –1S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17
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3
Table of contents
3.5
Checking the Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18
3.5.1
Checking safety equipment – Safety treadplate by machines with safety treadplate . . . . . . . . . . . . . . . . . . .
3-18
Moveable Guard for the Mould Area – Operator Side/ pneumatically actuated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19
3.6.1
Safety Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-20
3.7
Dangers from Tie Bar removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21
3.8
Fire fighting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21
3.6
II
BA027.01.1.en
Safety
3
Safety
3.1
General Safety Regulations
3
Service, maintenance, and repair work should only be carried out by personnel sufficiently qualified in their particular field and who have specific knowledge of injection moulding machinery. They should be versed in the maintenance of industrial health and safety standards, and they should be familiar with the construction and functioning of the necessary safety equipment on the machine. If necessary, enlist the help of our Service Department. Attention! The safety equipment fitted to the machine is there for your safety and that of the production ! The machine should only be operated if the safety equipment is in full working order ! To remove, by–pass or render safety equipment inoperative is therefore not permitted. If the safety equipment malfunctions or a fault occurs on it, the machine must be shut down immediately!
–1S42
–1Q0
Actuate Emergency Stop buttons –1S42 and –1S42.1
Main switch –1Q0
Close down the cooling water supply after approximately 20 min.
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3
Safety
General Safety Regulations – Continued The person in charge must be informed at once. Before putting the machine back into operation, the causes of the faults must be eliminated. We strongly recommend that checks me made on the Safety equipment in accordance with chap.3.5
3.1.1
Accident Prevention Regulations Injection moulding machinery is subject to several sets of Accident Prevention Regulations (UVV). This injection moulding machine operator (owner) is obliged to comply with these regulations. UVV Injection Moulding Machines VBG 7 a–c incl. Appendix 13.6 UVV General Regulations BGV A1 (till now VBG 1) UVV Power Driven Machinery VBG 5 UVV Electrical Units and Production Machinery BGV A2 (till now VBG 4) DIN EN 201 When an accumulator system is attached (Additional equipment) see chap. 3.3.1
3-2
BA027.01.1.en
Safety
3.1.2
3
Maintenance and Repair Work Attention! All repair and maintenance work should only be undertaken when main switch –1QO on the injection moulding machine is switched to ”O” and, if necessary, is locked by padlock, as well as the pressure in the hydraulic system is released and the is checked to be pressure free. On machines wtih accumulator system, see in addition also chap.3.3.1 Attention! In certain areas of the hydraulic systems it is possible, in spite of releasing pressure, for a residual pressure to remain. Therefore pay attention while opening hydraulic hoses and cylinders, disassembling of valves, etc. It is the employer’s duty to instruction the machine operator on the construction, operation and function of the safety equipment, as well as on any remaining danger areas and on the correct approach to health and safety at work. Horizontal areas on the machine are general not seen as floor space for operating and maintenance and must therefore not be entered while the machine is running. Areas, that can be entered while the machine is running, must comply with safety regulations and clearly marked. Attention! Any process which impairs safety on the machine should be stopped. The employer must ensure that no unauthorised personnel work on the machine. No safety equipment whatsoever must be taken off the machine or put out of action. If it is essential to remove safety equipment in order to carry out repair work, then DIN 57 105 regulations must be adhered to. When working on the electrical equipment, VDE 0105 regulations apply. As soon as repair work is completed, the safety equipment must be refitted and checked for effectiveness. Attention! No unauthorised conversion or modification of the safety equipment of the injection moulding machine is allowed.
BA027.01.1.en
3-3
3
3.1.3
Safety
Toxic gases, fumes or dustes Some plastic materials give off toxic gases, fumes or dustes when heated to excess. This applied particularly to PTFE (polytetrafluoroethylene), polymethyloxide and PVC. If these types of gases, fumes or dustes cannot be eliminated by adjusting machine settings, the operator of the machine has to install an effective extractor fan to divert them. As for as it is required fitting the extractor to the machine, contact Demag Plastics Group.
3.1.4
Explosive decomposition When exposed to prolonged heating, some plastic materials have a tendency to react by decomposing and becoming explosive. In particular, these are polymethyloxide and PVC. The types of plastic which react in this way should only be processed using nozzles and seals which open independently when pressure builds up (SVO, SVN) Prevention of accidents by: Adhering strictly to the prescribed processing parameters of the plastic materials in line with the material manufacturers’ specifications. In particular the processing temperature and dwell time in the plasticising cylinder. When processing heat sensitive plastics, the dwell times of the material in the plasticising cylinder should be minimised. When there is a break in production or material change, polyethylene should be used for purging (to cleanse the plasticising cylinder of any heat sensitive material). The heating should then be switched off.
3-4
BA027.01.1.en
Safety
3.1.5
3
Dangers from hot temperatures The fixed and moveable guard panels are normally very effective in preventing the operator from touching hot parts on the injection moulding machine or coming into contact with escaping melt. Once the guarding is open, particularly in the nozzle and mould area, the hot machine parts or plastic melt are then exposed. (The melt can also be forced out by a build up of gas in the plasticising cylinder or hot runner). In such cases, protective clothing must be worn by the technician e.g. safety gloves and headgear with visor.
3.1.6
Noise level of the machine Noise levels measurement according to EN ISO 3746 measured at the ”Operating position” in accordance with EN 201 – annex D, are listed in chap. 1.1. The values given apply to the largest drive unit which can be supplied for the respective size. The values indicated are measured in the manufacturer’s assembly plant when other noise producers are switch off. They can be considered general guidelines for other ambient conditions.
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Safety
3.2
Safety Equipment
3.2.1
Arrangement of Safety Equipment Demag modular 125/475 to 350/810 and 420/810 5
7
1
3
System 150/475 – 440
10 8 4
2
6
11 12
9
Picture 13: Safety equipment
Position
3-6
Description
1
moveable guard in the mould area – operator side
2
moveable guard in the mould area – non–operator side
3
moveable guard in the nozzle area – operator side
4
moveable guard in the nozzle area – non–operator side
5
fixed guard on the clamping system – operator side
6
fixed guard on the clamping system – non–operator side
7
fixed guard on the clamping system – front face
8
hinged and fixed guard on the ejection chute – operator side
9
fixed guard on the ejection chute non–operator side
10
fixed guard on the ejection chute – front face/moving mould half
11
fixed guard on the plasticising cylinder
12
moveable guard on the plasticising cylinder
BA027.01.1.en
Safety
3.2.1.1
3
Arrangement of Safety Equipment Demag modular 420/800, 500/900 to 800/1120 10
1
4
3
6 7
9
8
2
5
Picture 14: Safety equipment
Position
Description
1
moveable guard in the mould area – operator side
2
moveable guard in the mould area – non–operator side
3
moveable guard in the nozzle area
4
fixed guard on the clamping system – operator side
5
fixed guard on the clamping system – non–operator side
6
fixed guard on the clamping system – front face
7
fixed guard on the ejection chute – front face/moving mould half
8
fixed guard on the plasticising cylinder
9
moveable guard on the plasticising cylinder
10
fixed guard on the clamping system – bar
BA027.01.1.en
3-7
3
Safety
3.2.1.2
Arrangement of Safety Equipment Demag modular 1000/1400 up to 2000/1800 11
5
1
13
3
7 8
10
9
4
12
2
6
Picture 15: Safety equipment
Position
3-8
Description
1
moveable guard in the mould area – operator side
2
moveable guard in the mould area – non–operator side
3
moveable guard in the nozzle area – operator side
4
fixed guard in the nozzle area – non–operator side
5
fixed guard on the clamping system – operator side
6
fixed guard on the clamping system – non–operator side
7
fixed guard on the clamping system – front face
8
fixed guard on the ejection chute – front face/moving mould half
9
fixed guard on the plasticising cylinder
10
moveable guard on the plasticising cylinder
11
fixed guard on the clamping system – bar
12
foot operated safty platform
13
mechanical locking pawl
BA027.01.1.en
Safety
3.2.2
3
Description of Safety Equipment The safety equipment consists of guard panels and interlock mechanisms The guard panels prevent access to hazardous areas and protect personnel from plasticised melt spurting out. When a particular guard panel is opened or steping on to the foot operated safty platform, the interlock mechanisms block any associated hazardous machine movements. Attention! The measurements for the moveable guarding in the mould area and for the component ejection opening are designed in such a way that there is sufficient safety margin, provided the mould dimensions are smaller than or equal to the platen measurements. Additional safety measures are required for larger moulds where access above and below is concerned.
3.2.2.1
Moveable guard in the mould area – operator side The operator side is that from which a machine cycle can be initiated. When a moveable guard panel is opened, any hazardous movement is blocked i.e. ”Mould Close”, ”Mould Nozzle Forward”, ”Injection”, ”Hydraulic Ejector Forward” and ”Move Cores”. The blocking of the ”Mould Close” function is effected using two systems, one hydraulic and one electrical. The blocking of other movements occurs through the electrical system only. Note: In line with EN 201 European Safety Regulations the functions of non– return valve 2RV5, directional control valve 2SH4 and positioning switches –2S1 and –2S2 are monitored each time the guard is opened and closed.
BA027.01.1.en
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3
Safety
Moveable guard in the Mould Area – Operator side – Continued Error message: If the machine is started up and a moveable guard panel is left open, the following error message appears on the Ergocontrol: ”Guard doors not closed”. Depending on the fault in the hydraulic or electrical circuit, the following error messages are given on the Ergocontrol: 1.
”Hydr. mould safety problem”..., if a fault occurs on–return valve 2RV5.
2.
”Safety door end switch problem –2S1,–2S2 , –2S3”..., if a fault occurs on the limit switches on the moveable guard.
Effects and Fault Elimination: Ref. 1. When stroke cam ”Mould–open–Stop” is reached, the pump motor is switched off. When the cause has been eliminated, the fault must be cancelled by opening and closing the moveable guard on the operator side. Ref. 2. The pump motor is switched off. When the cause has been eliminated, the fault must be cancelled by closing and opening the moveable guard on the operator side. When the cooling time has elapsed the guard can be opened without interrupting the operating sequence (important when manual removal of mouldings applies). Not applicable on machines equipped to comply with French and American safety standards.
3-10
BA027.01.1.en
Safety
3.2.2.2
3
Safety treadplate (from Demag modular 1000/1400) When steping on to the safety treadplate, the pump motor switches off. Note: In line with EN 201 European Safety Regulations the function of the safety treadplate is monitored by switches –2S6.1 and –2S6.2 res. safety relay –1K50.... (by machines with safety treadplate) each time stepping on to the safety treadplate.
3.2.2.3
Mechanical locking pawl (from Demag modular 1000/1400) This safty device prevents an unintentional closing of the moveable guard – mould area operator side – and is effected by each opening movement. Lifting the locking pawl the moveable guard is closed, after that a new cycle can be started. Note: In line with EN 201 European Safety Regulations the function of the locking pawl is monitored by switches –2B237 and –2B238 each time the pawl is moved.
3.2.2.4
Moveable Guard in the Mould Area – Non Operator Side The guard on the non–operator side is monitored using two counter– controlled limit switches –2S1.2 and –2S2.2. As soon as the guard is opened, the pump motor switches off (Emergency–Stop Function) Demag modular 125/475 up to 800/1120: Only when the guard is closed on the non–operator side can the motor be restarted. from Demag modular 1000/1400: Only when the guard is closed on the non–operator side and subsequently the push–button –2S43 is pressed can the motor be restarted. Error Message: If an attempt is made to switch the motor on with the guard open on the non–operator side or the guard is closed, but the push–button –2S43 is not pressed, the following indiction is given on the Ergocontrol ”Guard on non–operator side not closed”
BA027.01.1.en
3-11
3
3.2.2.5
Safety
Moveable Guard in the Nozzle Area – Operator Side This guard prevents access to any pinch points during the nozzle forward movement, and contact with the hot nozzle or with any jets of material. If the guard is opened during manual operation, the following functions are blocked– ”Nozzle Forward”, ”Nozzle return”, ”Injection” an ”Plasticising”. During semi–automatic and automatic operation the cycle can be restarted by actuating the start key. Once the guard has been closed the cycle can be restarted by actuating the start key. Limit switch –3S3.1 ensures protection. This limit switch is actuated when the guard is opened and released again when the guard is closed. Error Message: If an attempt is made to re–start the cycle with the nozzle guard still open, the following message appears on the Ergocontrol: ”Nozzle guard not closed”.
3.2.2.6
Moveable Guard in the Nozzle Area – Non Operator side This guard prevents access to any pinch points during the nozzle forward movement, and contact with the hot nozzle and any hot jets of material. If the swing–back guard is opened during manual operation, the following functions are interrupted – ”Nozzle Forward”, ”Injection” and ”Plasticising”. During semi–automatic and automatic operation the cycle is interrupted. Once the guard has been closed the cycle can be restarted by actuating the Start Key. Limit switch –3S3.2 ensures protection. This limit switch is actuated when the guard is opened and released again when the guard is closed. Error Message: If an attempt is made to re–start the cycle with the nozzle guard still open, the following message appears on the Ergocontrol: ”Nozzle guard open – rear side”:
3-12
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Safety
3.2.2.7
3
Moveable Guard – Plasticising Cylinder This guard prevents access to any pinch points during the srew movement.
3.2.2.8
Fixed Guard – Plasticising Cylinder Fixed guard is fitted over the heater bands on the plasticising cylinder. This guards against accidental contact with hot parts of the cylinder.
3.2.2.9
Fixed Guard All fixed guards are screwed on and must not be removed.
3.2.2.10
Other hazards with the guards open in the nozzle area – Operator and Non–Operator side If the hopper bracket is moved and the material supply interrupted, there is a fire risk at the feed opening because of the build–up of heat in the plasticising cylinder. The hot nozzle and the build up of heat in the heater bands creates a fire risk in the nozzle area. Attention! Protective gloves and safety glasses must be worn when working on the hot plasticising cylinder.
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3
3.3
Safety
Hydraulic Safety Equipment
1MA1
Main manometer
The hydraulic safety equipment consists mainly of pressure relief valves (DB) or pressure adjusting valves (DE), which are set and sealed to a specific maximum permissible pressure. The valves are actuated if the pressure is exceed (as specified in the hydraulic diagrams). Pressure relief valve 1DB1 limits the max. hydraulic pressure. Max. closing pressure in clamping cylinder 2ZY1 is set on pressure relief valve 2DB1. Attention! These values protect the machine against overloading. Under no circumstances must they be adjusted.
3-14
BA027.01.1.en
Safety
3.3.1
3
Accumulator System (Additional Equipment) The accumulator system of the injection moulding machine conforms to the TRB (Technical Regulations for Pressure Vessels). The pressure vessels conform to the pressurised equipment guidelines 97/23/EC. Commissioning and test intervals are to be carried out according to the regulations applying in each country. The accumulator unit (4SP1) includes components which are subject to testing in line with the regulations. These elements must be checked on site at the manufacturer’s by inspectorate from the region or country of destination. Safety valve 4DB1, a tested design, forms part of the structure of the accumulator unit. This safety valve is set and sealed at 200 bar. It safeguards the entire pressure accumulator system against an excessive increase in pressure. The test certificates for the pressurised container and the safety valve are delivered with the machine. The operator must have the accumulator unit tested and approved by the appropriate inspectorate. This must be done after installation but before the unit is put into operation. When the machine is switched off, the accumulator clears itself automatically. Attention! Before carrying out any maintenance or repair work on the machine hydraulics, manual relief valve 4SA4 must be opened.
BA027.01.1.en
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3
3.4
Safety
Electrical Safety Equipment Emergency – Stop
–1S42
The electrical safety equipment consists mainly of earth wire connections, cover plates on parts which are hazardous to touch, and the Emergency – Stop button.
3.4.1
VDE – Regulations The electrical installation of our machines is in accordance with VDE regulations (Association of German Electrical Engineers). The operator and employer are also obliged to observe these regulations. The most important regulations are to be found in: Stipulations for the Operation of High–Voltage Power Units VDE 0105/ DIN 57 105.
3.4.2
Earth Wire Connections Earth wire connections on all electrical equipment on the machine, particularly electrical heating equipment, heater bands (jacketed and nozzle heater bands) must be checked periodically at times appropriate to the operation, to ensure that they are in good working order.
3-16
BA027.01.1.en
Safety
3.4.3
3
Emergency–Stop button –1S42 Function If one of the red buttons is depressed, all machine movements cease immediately. The pump motor and plasticising cylinder heating also switch off. Any handling equipment fitted via the standard interface will also be switched off. For safety reasons, once the Emergency–Stop button has been actuated, it remains locked in the depressed Stop position. The Ergocontrol shows the error message ”Emergency–Stop actuated”. By turning the red knob to the right, the lock is released. Connection point
BA027.01.1.en
–
Ergocontrol – operator side
–
Electrical distribution box –X19 – non–operator side
–
Mould internal area – operator side and non–operator side (only from Demag modular 1000/1400)
3-17
3
3.5
Safety
Checking the Safety Equipment The safety features built into the machine correspond to UVV Safety Regulations as laid down by the German Employers Liability Insurance Association (VBG) and to EN 201 (see chap.3.1.1) Attention! When a customer accepts a machine, the responsibility for servicing and testing the safety equipment passes to him. If faults are discovered on the safety equipment, the machine must be shut down immediately! The causes of the faults must be eliminated before the machine is put back into operation. The locking mechanism on the guard door in the mould area (operator side) are automatically monitored each time the guard is operated. Any faults are shown on the screen (see chap. 3.2.2) A routine check is only necessary, therefore, when the guard door remains closed for an extended period of time. Opening the guard door whilst the machine is in operation serves as a sufficient check. The moveable guard in the mould area (non–operator side) and the moveable guard in the nozzle area (operator and non–operator side) are not monitored. Again, a check can be made by opening the relevant guard and seeing whether hazardous machine movements are interrupted. Attention! It is the customer’s duty to ensure when modifications are made or peripheral units are added on etc. that the UVV Accident Prevention Regulations, as laid down by the German Employers Liability Insurance Association (VBG), and EN 201 and VDE specifications are complied with.
3.5.1
Checking safety equipment – Safety treadplate by machines with safety treadplate The function of the treadplate must be checked daily. The treadplate must be tested with a weight of at least 30 kgs. After the guard door (mould area) has been closed the pump must not be in operation.
3-18
BA027.01.1.en
Safety
3.6
3
Moveable Guard for the Mould Area – Operator Side/ pneumatically actuated.
Moveable Guard – Closing/Opening
This equipment makes opening and closing the moveable guard easier for the operator. Manual operation – and Setting–Up Process till Demag modular 800/1120: The guard is closed and opened only for as long as the relevant key is depressed. from Demag modular 1000/1400: The guard is closed only far as long as the locking pawl is lifted. The guard is opend only for as far as the relevant key is depressed.
Semi–Automatic operation till Demag modular 800/1120: Closing the moveable guard by actuating the Start key. from Demag modular 1000/1400: Closing the moveable guard by lifting the locking pawl. Note: The machine cycle is not initiated by closing the moveable guard. The machine cycle is begun by re–actuating the start key and with the moveable guard closed. Opening the moveable guard after Mould–Open–Stop and the end of ejector movement.
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3
3.6.1
Safety
Safety Rails
m
Picture 16: Safety rails on the moveable guard
The moveable guard is fitted on its front face with a safety rail m. If, during the mould closing movement, on safety rail m the moveable guard is obstructed, the closing movement changes direction and becomes an opening movement. Compressed Air – Setting Air pressure for machine movements is firmly set and sealed by the manufacturer Attention! Under no circumstances must the air pressure setting be increased. Risk of crushing between rails and Ergocontrol !
3-20
BA027.01.1.en
Safety
3.7
3
Dangers from Tie Bar removal
Picture 17: Automatical Tie Bar Removal
The Tie Bar Removal enables the installation of injection moulds which are larger than the daylight distance between tie bars. The Tie Bar Removal can be executed –
manually (see chap. 5.2.2.1.1)
or –
automatically when ”ZE 265 Automatical Tie Bar Removal” is available.
Attention! When releasing tie bar retraction movements the operator of the machine is responsible for protecting the danger area (e.g. moveable guards), which could result through tie bar retraction and that no person is within the danger area.
3.8
Fire fighting device In case of machines which have caught fire it is necessary to use fire fighting materials which are suitable for hydraulic oil and plastic.
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Table of contents
4
4
Operation 4.1
Operation general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.2
The Ergocontrol Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4.2.1
Layout of Ergocontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4.2.2
Screen–Saver shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4.2.3
Page selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
4.2.4
Function–Group keys & softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
4.2.5
Setting and function of the numeric keypad, Shuttle wheel and the Cursor–Move keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
4.2.6
Manual Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
4.2.7 4.2.7.1 4.2.7.2
Mode selection switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode selection switches – machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode selection switches – Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10 4-10 4-10
4.2.8
Q–Key (Quality Key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11
4.2.9
Emergency stop, Mould heating – , Barrel heating – , Pump ON – OFF . . . .
4-12
4.2.10
Start button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13
4.2.11
Chip–Card Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14
4.2.12
Integral Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15
4.2.13
Disc drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17
4.3
Program– and Data–disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
4.3.1
Loading Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
4.3.2
Help Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
4.3.3
Saving mould–setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
4.4
Page Layout, Release of Operating and Access Level . . . . . . . . . . . . . . . . . .
4-21
4.4.1
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
4.4.2
Release of Screen Page for Operation via Password Input / Chip–Card . . .
4-23
4.4.3
Access/ Password Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24
4.5
Description of the Screen Pages and their Operation . . . . . . . . . . . . . . . . . . .
4-25
4.5.1
Screen page ”0 MAIN MENU” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-25
4.5.2
Screen page ”1 MACHINE” – Machine Configuration . . . . . . . . . . . . . . . . . . .
4-26
BA027.01.1.en
I
4
Table of contents
4.5.3
Screen page ”3 VDMA 24468” – Standardized Parameter Screen page . . .
4-27
Functions – Group Mould – Description of the Screen Pages . . . . . . . . . . . . Screen page ”10 MOULD SETUP” – Setting Parameters and program preselect Clamping Unit and changing of Softkey Line . . . . . . . . . . 4.5.4.1.1 Screen page ”10 MOULD SETUP” – changing of Softkey Line . . . . . . . . . . . 4.5.4.1.2 Axis monitoring (drift monitoring) for Mould opening and closing . . . . . . . . . . 4.5.4.1.3 Setting Parameters Clamping Unit – mould speed / mould safety force . . . . 4.5.4.1.4 Mould – Setting Parameters Clamping Unit – mould safety end . . . . . . . . . . 4.5.4.1.5 Program preselector Switch Clamping Unit – Mould safety (System machines only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.1.6 Mould – Setting Parameters Clamping Unit – mould safety repeat . . . . . . . . 4.5.4.1.7 Setting Parameters Clamping Unit – clamping force . . . . . . . . . . . . . . . . . . . . 4.5.4.1.8 Setting Parameters Clamping Unit – Side core safety mechanism . . . . . . . . 4.5.4.1.9 Setting Parameters Clamping Unit – mould cooling switched off . . . . . . . . . . 4.5.4.1.10 Setting Parameters Clamping Unit – discharge control . . . . . . . . . . . . . . . . . . 4.5.4.1.11 Setting Parameters Clamping Unit – setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.1.12 Adjustment of mould height and clamping force . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.2 Screen page ”120 MOULD SAFETY” (system machines only) – Setting Parameters and Program preselector Switches Clamping Unit . . . . 4.5.4.3 Programming of Mould Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.3.1 Screen page ”16 MOULD: ..... ” – Programming of Mould Sequence . . . . . . 4.5.4.3.1.1 Programming of the Basic Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.3.1.1.1 Programming of the ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.3.1.1.2 Programming of cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.3.1.1.3 Programming of safety gate movement and start button . . . . . . . . . . . . . . . . . 4.5.4.3.1.2 Programming of the Flexible Sequence without / with Repetition(s) . . . . . . . 4.5.4.3.2 Screen page ”17 SEQUENCE PARAMETER” – setting parameters . . . . . . . 4.5.4.3.2.1 Switching parameter display with a multiply programmed stroke dependent sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.3.2.2 Screen page ”17 SEQUENCE PARAMETER” – Actual value display . . . . . . 4.5.4.4 Screen page ”13 MOULD DIRECT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.4.1 Step Mode of Mould Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.4.2 Direct Mode of Ejector and Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.5 Screen page ”11 EJECTOR” Setting Paramerters and Progr. Preselector Switches for Ejector . . . . . . . . . 4.5.4.5.1 Ejector – Setting Paramerters strokes, pressures, speeds and times . . . . . . 4.5.4.5.2 Ejector – Setting Paramerter ”Multi–Stroke” and ”Multi–Stroke back stop” . . 4.5.4.5.3 Ejector – program preselect ”Ejector” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.5.4 Ejector – program preselect ”parallel with mould” . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.5.5 Ejector – program preselect ”Set zero datum” . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4.5.6 Ejector – program preselect ”Switch OFF at end position” . . . . . . . . . . . . . . . 4.5.4.5.7 Ejector – program preselect ”Ejector in the mould” . . . . . . . . . . . . . . . . . . . . .
4-29
4.5.4 4.5.4.1
II
4-29 4-30 4-30 4-31 4-33 4-33 4-35 4-35 4-35 4-36 4-36 4-36 4-37 4-40 4-42 4-42 4-45 4-46 4-48 4-50 4-52 4-54 4-55 4-56 4-57 4-58 4-58 4-59 4-60 4-61 4-61 4-62 4-63 4-63 4-64
BA027.01.1.en
Table of contents
4.5.4.5.8 4.5.4.5.9 4.5.4.5.10 4.5.4.5.11 4.5.4.5.12 4.5.4.6 4.5.4.6.1 4.5.4.6.2 4.5.4.6.3 4.5.4.6.4 4.5.4.6.5 4.5.4.6.6 4.5.4.6.7 4.5.4.6.8 4.5.4.6.9 4.5.4.7 4.5.4.7.1 4.5.4.7.2 4.5.4.7.3 4.5.4.7.4 4.5.5 4.5.5.1 4.5.5.1.1 4.5.5.1.2 4.5.5.1.3 4.5.5.1.4 4.5.5.2 4.5.5.2.1 4.5.5.2.2 4.5.5.2.3 4.5.5.3 4.5.5.3.1 4.5.5.3.2 4.5.5.4 4.5.5.4.1 4.5.5.5 4.5.5.5.1
BA027.01.1.en
Ejector – program preselect ”Multistroke with handling” . . . . . . . . . . . . . . . . . Ejector – program preselect ”Monitoring position active” . . . . . . . . . . . . . . . . . Ejector – program preselect ”Stroke blocked at rejects” . . . . . . . . . . . . . . . . . Ejector – program preselect ”Without release handling” . . . . . . . . . . . . . . . . . Ejector – program preselect ”QC–Plotting switch at stroke” . . . . . . . . . . . . . . Screen page ”14 CORES” – Setting Paramerters and program preselect . . Core–Setting Paramerters strokes, pressures, speeds and times . . . . . . . . . Change–over of the parameter display with multi–programmed position–dependent sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actual value display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cores – program preselect ”Core control on” . . . . . . . . . . . . . . . . . . . . . . . . . . Cores – program preselect ”Move parallel with” . . . . . . . . . . . . . . . . . . . . . . . . Cores – program preselect ”Without release handling” . . . . . . . . . . . . . . . . . . Cores – program preselect ”Switch OFF in end position” . . . . . . . . . . . . . . . . Cores – program preselect ”Time dependant” . . . . . . . . . . . . . . . . . . . . . . . . . . Cores – program preselect ”Rotating core” . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”12 PNEUMATIC VALVES” – Programming, Setting Paramerters and Program Preselector Switches . . . . . . . . . . . . . . . . . Pneum. valves – Programming of Switch on– / Switch off events . . . . . . . . . Pneumatic valves – Setting Paramerters Delay Times . . . . . . . . . . . . . . . . . . Pneumatic valves – Program preselector Switch ”Valve active” . . . . . . . . . . . Pneumatic valves – Program preselector Switch ”Key active” . . . . . . . . . . . . Functions – Group Injection – Description of the Screen Pages . . . . . . . . . . Screen page ”20 PROCESS OPTIMIZATION” – Setting Parameters, Program Preselect and Indication of Accumulator Operation . . . . . . . . . . . . . Process optimization – Setting Parameters for Injection Unit . . . . . . . . . . . . . Process optimization – program preselect ”Injection–, Holding– and Dosing– Profile” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process optimization – program preselect for switch over from injection to follow–up pressure, as well as monitoring of switch over . . . . . . . . . . . . . . . . Process optimization – Indication of Accumulator Operation . . . . . . . . . . . . . Screen page ”21 DOSING–PROFILES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOSING–PROFILES – Setting Paramerters . . . . . . . . . . . . . . . . . . . . . . . . . . . Program preselct ”Stage” – Switch ON and OUT of Profile Stages . . . . . . . DOSING–PROFILE – Shifting of Dosing Profiles . . . . . . . . . . . . . . . . . . . . . . . Screen page ”26 INJECTION PROFILE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program preselect ”Stage” – Switch ON / OUT of Profile Stages . . . . . . . . . INJECTION–PROFILE – Shifting of Injection Profiles . . . . . . . . . . . . . . . . . . . Screen page ”27 HOLDING–PROFILE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program preselect ”Stage” – Switch ON / OUT of Profile Stages . . . . . . . . Screen page ”23 INJECTION UNIT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INJECTION UNIT – Setting Parameters Injection Unit . . . . . . . . . . . . . . . . . .
4
4-64 4-64 4-65 4-65 4-65 4-66 4-68 4-70 4-71 4-72 4-72 4-73 4-73 4-73 4-73 4-74 4-76 4-81 4-81 4-81 4-82 4-82 4-82 4-83 4-83 4-85 4-86 4-87 4-89 4-90 4-91 4-93 4-93 4-94 4-95 4-96 4-96
III
4
Table of contents
4.5.5.5.2 4.5.5.5.3 4.5.5.5.4 4.5.5.6 4.5.5.6.1 4.5.5.6.2 4.5.5.6.3 4.5.5.7 4.5.5.8 4.5.6 4.5.6.1 4.5.6.1.1 4.5.6.1.2 4.5.6.1.3 4.5.6.2 4.5.6.2.1 4.5.6.2.2 4.5.6.2.3
4.5.6.2.4
4.5.6.3 4.5.6.4 4.5.7 4.5.7.1 4.5.7.1.1 4.5.7.1.2 4.5.7.2
4.5.7.3 4.5.7.4 4.5.7.5 4.5.7.6 4.5.7.6.1 4.5.7.6.2
IV
INJECTION UNIT – Program preselect ”Retract before/after dosing” . . . . . INJECTION UNIT – Manual movement of Injection Unit . . . . . . . . . . . . . . . . . INJECTION UNIT – Switch ”Set zero datum” . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”24 MWE” – MWE Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MWE Scanner – general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MWE Scanner – Profile Representation and Changing of Softkey Line . . . . MWE Scanner – Softkey Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”25 MWE CONFIGURATION” – MWE scanner – Parameter selection / – settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”28 INTRUSION” – Intrusion and Remove cold–slug . . . . . . . .
4-99 4-99 4-100 4-101 4-101 4-102 4-103
Functions – Group Temperatures – Description of the Screen Pages . . . . . . Screen page ”30 TEMPERATURES” – Setting Parameters Barrel and Oil Temperatures, Cold start protection as well as Program Selectors . . . . . Temperatures – Switching ON and OFF of barrel heating . . . . . . . . . . . . . . . . Temperatures – Setting Parameters Barrel and Oil Temperatures, Cold start protection and Graphical representation . . . . . . . . . . . . . . . . . . . . . Temperatures – Program preselect ”Heating monitoring”, ”Temperature reduction”, ”Oil prewarming” and ”Control by wire breaks” . . . Screen page ”31 HOT RUNNER 1–16” and ”32 HOT RUNNER 17–32 ”– Hot Runner – Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperatures – Switching ON and OFF of hot runner heating as well as start–up characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Runner – Lettering of Hot Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperatures – Setting ”Hot runner temp.”, ”Soft start temp.”, ”Temp. reduction” and ”Boost temperature” and Boost time settings. Boost time remaining, ”Prop. % Hand” and ”Slave” . . . Hot Runner – Program preselector Switches ”Heating monitoring”, ”Boost”, ”Startup protect”, ”Startup protect”, ”Set control load” and ”Synchronous heating” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”38 CONDITIONING UNIT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”33 MOULD HEATING” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-108
Functions – Group Program – Description of the Screen Pages . . . . . . . . . . Screen page ”40 PRESELECT PROGRAMS” . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”40 PRESELECT PROGRAMS” – Program Preselect . . . . . . . Screen page ”40 PRESELECT PROGRAMS” – Changing of Softkey Line . Screen page ”41 SWITCH–ON PROGRAM” – Programming of Switching ON for Oil prewarming, Cylinder heating, Socket combination as well as Mould temperature . . . . . . . . . . . . . . . . . . . . . Screen page ”42 STARTUP PROGRAM” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”43 PURGING PROGRAM” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”44 SWITCH OFF MATRIX” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”45 MOULD CATALOGUE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To format a disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-105 4-107
4-108 4-108 4-109 4-112 4-115 4-115 4-117 4-118
4-121 4-124 4-128 4-130 4-130 4-130 4-131 4-132 4-135 4-137 4-139 4-141 4-142 4-143
BA027.01.1.en
Table of contents
4.5.7.6.3 4.5.7.6.4 4.5.7.6.5 4.5.7.7 4.5.7.7.1 4.5.7.7.2 4.5.7.7.2.1 4.5.7.7.2.2 4.5.7.7.2.3 4.5.7.7.3 4.5.7.8 4.5.7.9 4.5.8 4.5.8.1 4.5.8.1.1 4.5.8.1.2 4.5.8.1.2.1 4.5.8.1.2.2 4.5.8.1.2.3 4.5.8.1.3 4.5.8.2 4.5.8.2.1 4.5.8.2.1.1 4.5.8.2.1.2 4.5.8.2.2 4.5.8.2.3 4.5.8.2.3.1 4.5.8.2.3.2 4.5.8.3 4.5.8.4 4.5.8.5 4.5.8.5.1 4.5.8.5.2 4.5.8.6 4.5.8.6.1 4.5.8.6.1.1
BA027.01.1.en
4
Reading a disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”99 ERGOSTART” – Machine pre–setting . . . . . . . . . . . . . . . . . Screen page selection, input sequence and softkey functions . . . . . . . . . . . . Input data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting the material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering the weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering geometry data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ergostart flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”101 PROZESS–INFORMATION” – Note on optimisation and setting of machine parameters . . . . . . . . . . . . . . . . Screen page ”102 EXPERTENSYSTEM” – Note on remedies for quality defects on the mouldings . . . . . . . . . . . . . . . . . .
4-145 4-146 4-148 4-149 4-150 4-154 4-154 4-155 4-156 4-157
Functions – Group Process – Description of the Screen Pages . . . . . . . . . . . Screen page ”52 CONT. PROCESS CONTROL” . . . . . . . . . . . . . . . . . . . . . . . Screen Page ”52 CONT. PROCESS CONTROL” – changing of Softkey Line Screen page ”52 CONT. PROCESS CONTROL” – Warning Limits . . . . . . . . Automatic calculation of warning limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and stopping the warning limit monitoring . . . . . . . . . . . . . . . . . . . . . . Adopting warning limits as quality limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”52 CONT. PROCESS CONTROL” – Warning limit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS – STATISTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”50 PROCESS – STATISTIC 1” . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”50 PROCESS – STATISTIC 1”, tabular representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”50 PROCESS – STATISTIC 1”, grahpical representation . . . . Screen page ”51 PROCESS – STATISTIC 2” . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”53 STATISTIC – CONFIG.” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”53 STATISTIC – CONFIG.” – Programming of channel . . . . . Screen Page ”53 STATISTIC – CONFIG.” – Program preselector switch ”Saving data to diskette” . . . . . . . . . . . . . . . . . . . Screen page ”54 PRODUCTION COUNTERS” . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”55 ENERGY METERING” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”56 ANALYSIS OF CYC. TIME” . . . . . . . . . . . . . . . . . . . . . . . . . . ANALYSIS OF CYC. TIME – Programming, Deleating and Saving as well as Reading of Parameters . . . . . . . . . . . . . . . . ANALYSIS OF CYC. TIME – Start / Stop and deletion of record . . . . . . . . . . SPC – Statistical Process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”58 SPC – CONFIGURATION” . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”58 SPC – CONFIGURATION” Selection of monitored parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-164 4-164 4-166 4-167 4-169 4-173 4-173
4-159 4-161
4-174 4-177 4-177 4-177 4-179 4-181 4-183 4-184 4-186 4-187 4-190 4-192 4-193 4-194 4-195 4-195 4-199
V
4
Table of contents
4.5.8.6.2 4.5.8.6.2.1 4.5.8.6.2.2 4.5.8.6.2.3 4.5.8.6.3
Screen page ”59 SPC CONTROL CHART” . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scaling Control chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPC Control Chart, Selection of representative random sample . . . . . . . . . . SPC Control Chart, Scaling the control charts and show values . . . . . . . . . . Printing of the SPC – Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-200 4-200 4-201 4-202 4-203
4.5.9 4.5.9.1 4.5.9.2 4.5.9.3 4.5.9.3.1 4.5.9.3.2 4.5.9.3.3 4.5.9.3.4 4.5.9.4 4.5.9.4.1 4.5.9.4.2 4.5.9.4.3 4.5.9.4.4
Function – Group Automation – Description of the Screen Pages . . . . . . . . . Screen page ”60 QC – PLOTTING” – Quality monitoring . . . . . . . . . . . . . . . . Screen page ”46 PROGRAM INPUTS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”47 PROGRAM OUTPUTS” and ”48 PROGR. OUTP. 5,6” . . . Progr. outputs – Programming of Switch on–/Switch off events . . . . . . . . . . . Programmable outputs – Setting parameter delay times . . . . . . . . . . . . . . . . Programmable outputs – Program preselector Switch Output ”aktiv” . . . . . . Programmable outputs – Program preselector Switch ”Softkey aktiv” . . . . . CAP Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”65 CAP – ORDER”, Job – Computer aided Production . . . . . Screen page ”67 CAP – SHIFT” – Computer aided Production . . . . . . . . . . . Screen page ”68 CAP – REJECTS” – Computer aided Production . . . . . . . . Screen page ”69 CAP – STATISTIC” – Computer aided Production . . . . . . .
4-204 4-205 4-208 4-212 4-215 4-221 4-221 4-221 4-222 4-222 4-224 4-226 4-227
4.5.10 4.5.10.1 4.5.10.1.1 4.5.10.1.2
Function – Group Handling – Description of the Screen Pages . . . . . . . . . . . Screen page ”78 ROBOT – EUROMAP 67” . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”78 ROBOT – EUROMAP 67” – IMM Operation Display . . . . . Screen page ”78 ROBOT – EUROMAP 67” – Handling mode display . . . . .
4-228 4-228 4-229 4-232
4.5.11 4.5.11.1 4.5.11.2 4.5.11.2.1 4.5.11.2.1.1 4.5.11.2.1.2 4.5.11.2.1.3 4.5.11.2.1.4
Function – Group Information – Description of the Screen Pages . . . . . . . . . Screen page ”80 PAGE LAYOUT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETUP – Screen pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”83 SETUP” – Setting of general functions . . . . . . . . . . . . . . . . . Screen page ”83 SETUP” – Setting of ”Button click” . . . . . . . . . . . . . . . . . . . . Screen page ”83 SETUP” – Setting of ”Screen saver shutdown” . . . . . . . . . . Screen page ”83 SETUP” – Setting of ”Alarm page automatic” . . . . . . . . . . . Screen page ”83 SETUP” – Setting of ”Amendment report log” and set–up of change reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”83 SETUPP” – Setting of Release of Screen Page for Operation via Password Input / Chip–Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”83 SETUP” – Setting of measurements . . . . . . . . . . . . . . . . . . . Screen page ”83 SETUP” – Setting of time and date . . . . . . . . . . . . . . . . . . . . Screen page ”83 SETUP” – Setting of printers and the page length . . . . . . . Screen page ”183 SETUP MACHINE” – PG–Switch for Release of programming of mould sequnce, axis monitoring and Screw–back stop Maximum . . . . . . . . . . . . . . . . . . . . . . . General text data – Indication and Typing of Text Informations . . . . . . . . . . . Screen page ”81 GENERAL DATA TEXT 1” . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”82 GENERAL DATA TEXT 2” . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-237 4-237 4-238 4-238 4-239 4-239 4-240
4.5.11.2.1.5 4.5.11.2.1.6 4.5.11.2.1.7 4.5.11.2.1.8 4.5.11.2.2
4.5.11.3 4.5.11.3.1 4.5.11.3.2
VI
4-240 4-241 4-242 4-242 4-243
4-248 4-250 4-250 4-252
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Table of contents
4.5.11.4 4.5.11.4.1 4.5.11.4.2 4.5.11.4.3 4.5.11.4.4 4.5.11.5 4.5.11.5.1 4.5.11.5.2 4.5.11.6 4.5.11.6.1 4.5.11.6.2 4.5.11.6.3 4.5.11.7 4.5.12 4.5.12.1 4.5.12.2 4.5.12.3 4.5.12.3.1
Screen page ”84 PRINTING” – Printing from Screen pages, Reports and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Start and interuption of a printing via Softkeys . . . . . . . . . . . . . . . . . . Manual Start of a printing via Manual Function Key ”Hardcopy” . . . . . . . . . . . Automatic Start of a printing according to selected program options . . . . . . . Selection of Pages to be printed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”87 PASSWORD” – Allocation and Configuration of a User Chip–Card . . . . . . . . . . . . . . . . . . . . . . Password – Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration of a User Chip–Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”85 SERVICE PAGE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”85 SERVICE PAGE” – Indication of Operating hours, Lubrication and Machine cycles, as like inspection diagram . . . . . . . . . . . . . . Screen page ”851 MAINTENANCE PROGRAM” – Display of inspection work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”852 MAINTENANCE PLAN” – Recording maintenance work Screen page ”86 AMENDMENT REPORT LOG” – Indication and Dropping of changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function – Group Service – Description of the Screen Pages . . . . . . . . . . . . Screen page ”90 FUNCTION CONTROL” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”91 STATUS TEST” – Bit Control . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”COMMISSIONING” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen page ”96 COMMISSIONING” – Dry cycle, Lubrication test, Commissioning , Optimising of cyclinder heating, Pump and Stroke commissioning . . . . . . . . 4.5.12.3.1.1 Optimisation of cylinder heating, hot runner– and mould heating . . . . . . . . . . 4.5.12.3.1.2 Pump Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.12.3.1.3 Stroke commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4-253 4-254 4-256 4-256 4-258 4-260 4-261 4-262 4-263 4-263 4-266 4-267 4-269 4-271 4-271 4-272 4-273
4-273 4-274 4-275 4-276
4.5.13 4.5.13.1
Function – Group Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-277 Screen page ”2 ALARM DISPLAY” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-277
BA027.01.1.en
VII
Operation
4
Operation
4.1
Operation general
4
The efficiency of our machine is founded essentially on the use of microprocessor control. In order to operate these control systems reliably, it is necessary to keep them free of all interference. We have suppressed possible sources of interference which could be produced by the machine itself by attenuation of electrical devices and the use of radio – shielded cables. Note: In the case of all analog valves, attenuators must not contain LED Check Lamps between the magnetic connectors and the connector sockets. Diodes in the adaptors lead to malfunction of the valves. With regard to sources of interference outside the machine, suitable measures must be taken by the user e.g. attenuation of peripheral devices (attenuators). For additional information refer to the electric circuit diagrams. Attention! Machines fitted with a toggle clamping system should not be stopped in the locked position or be left idle for any considerable length of time.
BA027.01.1.en
4-1
4
Operation
4.2
The Ergocontrol Console
4.2.1
Layout of Ergocontrol
LCD – Display
Function – group keys
Numeric keypad
Manual Function keys
Mode select. switches
Q – Key
Softkeys Menue– select. Function – group keys Cursor – move keys Shuttle wheel
Special functions keys Keys for Robot Chip–card reader
Emergency stop
Start Button
Integral Printer
Disk drive Disk box
4-2
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Pump, Barrel – Mouldheating, ON – Off
Operation
4.2.2
4
Screen–Saver shutdown The LCD Display is fitted with a florescent light strip to improve contrast. In order to improve the life of the strip (about 20000 h in continuous operation), it is automatically switched off after a set time (in minutes) providing there is no use of the console during that period. The time delay, in minutes (0–99) to switch–off is set on the page ’83 SETUP’ chap. 4.5.11.2.1 The light strip is immediately switched on again when any key is pressed on the console.
BA027.01.1.en
4-3
4
4.2.3
Operation
Page selection
LCD – Display
Softkeys Menue– select.
Function – group keys
Function – group keys Pages are selected using the following equipment: LCD Display Softkeys, to select a page inside a function group Function group keys Mould
Injection unit
Temperatur
Program– preselect I
O
I Automation
Handling
Process– control Process
Service
Information Service–control
Alarms
On selection of a function group key, the relevant page selections are shown. The page can then be selected using the appropriate softkey. Example: After selecting the function group ’MOULD’, the pages for the mould set–up are brought up. Using the appropriate Softkey, any page to do with mould set up can now be selected. With actuation of the softkey ”return” you return to the previously displayed screen page.
4-4
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4.2.4
BA027.01.1.en
00Mainmen.
Mould
Function–Group keys & softkeys
Process optimizing
Temperatur.
PG– preselect
Process
Process– Statistics 1
Quality monitoring
Robot– Status
i
Diagnosis
Information
Page layout
Function control
Operation
Service
Drive axis
Alarms
4
4-5
4
4.2.5
Operation
Setting and function of the numeric keypad, Shuttle wheel and the Cursor–Move keys Enlarge Reduce input input Enter key value value
Cursor keys next line / column to... up left
Input Keys
right Home Position down Shuttle wheel
Clear key
Selection of Setting Parameters Once a page has been selected, it is possible to move to any input field using the cursor–move keys or by rotating of Shuttle wheel. Note: The cursor movement keys have usual acceleration function when held down for longer than a single step. The cursor home position is made by the arrow in the middle of the cursor move keys.
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Operation
4
Setting and function of the numeric keypad, Shuttle wheel and the Cursor–Move keys – continuation Alter of Setting Parameters The set value can be altered using the numeric keypad or the shuttle wheel. Alter of Setting Parameters using the numeric keypad A required value is typed in via the numeric keypad at the input position (see Password, Chap 4.4.2). To speed the setting operation, the original value can be incremented or decremented using the numeric keypad arrows. The value is accepted by the system when one of the two E = Enter keys is pressed. Note: Whenever a new value is being typed into the input field, the top line of the page shows the MIN, MAX, and original values for that field. Alter of Setting Parameters using the shuttle wheel After pressing one of the two E keys E = Enter the required value can be changed at the input position by turning the shuttle wheel (see Password, chap.4.4.2). The value is accepted by the system when one of the two E = Enter keys is pressed.
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4-7
4
4.2.6
Operation
Manual Key
Hydr. screw retraction
Injection EE2
Nozzle Advance – Return
Nozzle EE2 Advance – Return Hydr. screw retraction EE2 F1 – F 16 for Spec. funct.
Injection Mould Open – Close
Mould rotation clamping elements in / out
Hydr. ejector Advance – Return
Pneum. Valves 1–4
Cores In – Out
Autom. safety gate Open – Close
Switch over to alphanumerical text input
Metering
Switch over to uppercase / lowercase by text input of help functions
Mould fitting height Larger – Smaller
Reference machine
Metering EE2
Printer Hardcopy
Mould rotation left right
Mould rotation register in / out The symbolic keys are used for Set–up and Manual operation of the machine. F...Nrn – keys Keys with ”F” numbers are reserved for special functions. ABC... – key The ”ABC...” key switches the Manual and ”F” keys into ASCII characters including letters. In ASCII mode the ”Shift” key selects capital letters. Note: The ASCII mode only works on text input screens such as, General Text Data 1 & 2, and the Mould Catalogue.
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Operation
4
Manual Key – continuation Reference – key With manual operation, the machine moves into the normal position after actuation of the reference key. Mould fully open Ejectors in base position according to sequence programming Cores in base position according to sequence programming Dosing stop reached
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4-9
4
4.2.7 4.2.7.1
Operation
Mode selection switches Mode selection switches – machine
Set – up
Automatic
Manual
Semi – Autom. The modes of operation are as follows: Set–up Manual Semi–Auto Automatic The mode can be selected directly by switch.
4.2.7.2
4-10
Mode selection switches – Robot
Step
Robot ON / OFF
Reference
Set – stop
Step:
Stepping mode in each axis
Reference:
All axes to base position
Set stop :
After the next operation the robot remains in the waiting position
I/0
Robot ON / OFF
:
BA027.01.1.en
Operation
4.2.8
4
Q–Key (Quality Key)
Q – Key
The Quality Key causes a quality record to be produced after a set number of shots. The set–up for the record is on the page ’60 QC – PLOTTING’ chap. 4.5.9.1
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4-11
4
Operation
4.2.9
Emergency stop, Mould heating – , Barrel heating – , Pump ON – OFF Mould heating ON – OFF
Barrel heating ON – OFF
Pump motor ON – OFF
Emergency stop
The emergency stop button brings the machine to a safe standstill. This involves; Pump motor OFF Barrel heating OFF Mould heating OFF In order to restart the machine, the corresponding green buttons must be pressed for: Pump ON Cylinder heating ON Mould heating ON It is also possible to switch these functions off individually by pressing the corresponding red buttons.
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Operation
4.2.10
4
Start button
Start Button
After selecting Automatic mode the machine is started with the Start button, and thereafter remains running in Automatic mode until stopped. This start up can only occur when the machine has been moved in Manual mode to its base position as follows: Mould fully open Ejectors in position according to sequence programming by mould fully open Cores in position according to sequence programming by mould fully open Dosing stop reached Robot outside of the mould area This start up restriction applies similarly in Semi–Auto mode, but in this case the start button must be pressed to commence each individual cycle.
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4-13
4
4.2.11
Operation
Chip–Card Reader
Chip–Card Reader
Chip–Card
The chip card reader installed in the Ergocontrol permits rapid release of the approved access level via chip card. Manual input of password code is unnecessary. Note: The respective access authorisations are specified in screen page ’87 PASSWORD’ (see chap. 4.5.11.5).
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Operation
4.2.12
4
Integral Printer
Integral Printer
The Ergocontrol integral printer is equipped with paper feeder for thermal paper. The paper roll is 112 mm wide by 25 m, and should allow the printouts from about 300 pages. Paper Specifications: Thermal Paper 112 mm / 25 m, Pack of 5 rolls B 00 25,4 PH, Grade: 00 138 centred end–of–roll warning stripe: TF 02 FJ Note: Thermal paper is not suitable for long–term storage. If a print is important then photocopy it. Note: The thermal paper supplied by Demag Ergotech is physiologically and toxicologically harmless when used according to instructions. Attention! Thermal paper of some paper manufacturers contains poisonous reactive chemicals. We recommend you wash your hands after handling this paper. If possible, make special arrangements for the disposal of any scrap paper. The following print functions are available: Printout from; Single pages A selection of pages Amendment report Alarm log All pages Print report Error log Change of operation mode Mould catalogue
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4-15
4
Operation
Integral Printer – continuation The options are set–up on the page ’84 PRINTING’ chap. 4.5.11.4 SPC control charts –see page ’58 SPC – CONFIGURATION’ chap. 4.5.8.6.1 CAP shift end and job end reports without central computer –see page ’67 CAP – SHIFT’ chap. 4.5.9.4.2 and ’65 CAP – ORDER’ and ’65 CAP – ORDER’ chap. 4.5.9.4.1 Any page that is displayed on the NC4 console can be printed using the printout button.
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Operation
4.2.13
4
Disc drive
Disk – drive Disk– box
The drive uses the following disks: 3.5 inch 1.44 Megabyte (MB) formatted High Density (HD) New disks must be formatted before use (unless they are bought pre– formatted) with either a virus–free personal computer, or using the disk drive within the Ergocontrol and the format option on the page ’45 MOULD CATALOGUE’ chap. 4.5.7.6 Attention! Formatting a used disk will destroy the original data. Note: Data life on the floppy disk is approx. 3 years, depending on usage, storage conditions, and regular cleaning of the floppy disk drive. We recommend, therefore, that appropriate back–up disks are made on an IBM compatible PC and then stored somewhere safe. The disk drive on the Ergocontrol has no copy facility. Attention! To avoid confusion, invalid disks (e.g. old software versions) have to be destroyed.
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4-17
4
Operation
Disk drive – continuation Vasrious functions can be carried out with disk. Loading Software Help Function Mould – Data saving Note: Loading of software, mould setting data and formating of disks is only possible, when the machine is not executing any functions. Note: Mould setting data from other machines have to be adapted if needed.
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Operation
4.3
Program– and Data–disks
4.3.1
Loading Software
4
Ergocontrol–Firmware Ergocontrol–Pages (Language module) SPS–Program through the Ergocontrol to the machine CPU controller Loading of the various software modules runs automatically as soon as the Ergocontrol console is switched ON with the disk in the drive (main switch machine –1Q0). Note: Loading of software, mould setting data and formating of disks is only possible, when the machine is not executing any functions.
4.3.2
Help Functions The help function is shown as a small window of 12 line by 62 characters overlaid on the originally selected page. Help is available in the following areas: currently active error messages the selected page Input values indicated by the cursor If the cursor is in the home position, then the drive will read the help disk when the help key is pressed and information relevant to the originally selected page will be displayed. However, help on any currently displayed error message will take priority over general page information. If the help key is pressed with the cursor at a particular input value, then help will be shown relating to that value.
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4-19
4
4.3.3
Operation
Saving mould–setting data All these functions relate to page ’45 MOULD CATALOGUE’ chap. 4.5.7.6: Load setting data from disk Archive setting data onto disk Delete setting data from disk Format a disk Note: Loading of software, mould setting data and formating of disks is only possible, when the machine is not executing any functions. Note: Mould setting data from other machines have to be adapted if needed.
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Operation
4.4
Page Layout, Release of Operating and Access Level
4.4.1
Page Layout
indication of access level
screen page number screen page titel
4
date/time field for error messages current operating function of the machine
field for setting and monitoring parameters
Softkeys Menue– select. The Ergocontrol pages are laid out in 3 sections: Heading Setting values and monitored values Softkeys The heading information includes the password access level or access level of inserted smart card at the top left. In the middle of the heading is the page number and title. Just under the title is the field for any error messages which are shown in inverse text. The upper right shows the current operating function of the machine in clear text, with time and date.
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4-21
4
Operation
Page layout – continuation The page number allows the operator to jump quickly from page to page without going through the function keys. After typing in the correct two digit number the desired page immediately appears. This function only works when the cursor is in the home position. There are 21 lines by 83 characters used for the setting and monitoring parameters. From the softkey line it is possible to select a page from within a function group. Additionally certain pages use the softkeys for special functions.
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Operation
4.4.2
4
Release of Screen Page for Operation via Password Input / Chip–Card If the settings are to be changed, a password must be typed–in first or a chip–card must be inserted. It is possible to type in the password or to insert the chip–card on any screen. Note: It is specified by the super–user in screen page ’83 SETUP’ whether operation is released via manual password input or chip card (see chap. 4.5.11.2.1). Release for operation via manual Password – Input Press the decimal point key ”.” Type in a 5 digit password (not displayed) Press the ”E” = Enter key If the password has been accepted, then the corresponding access level code will appear in the top left of the display. To block further setting changes: Press the decimal point key ”.” Press the ”C”=Cancel key the access level code disappears, and further changes are blocked. Whenever the screen–saver shutdown chap. 4.2.2 occurs the access level is also cancelled Password control and allocation is made under a Super–User. The set–up of these functions is on the page ’87 PASSWORD’ chap. 4.5.11.5. Release for operation via Chip–Card Insert Chip–card into Chip–card reader If the Chip–card has been accepted, then the corresponding access level code will appear in the top left of the display. If the Chip–card has been drawn out, then the access level code disappears, and further changes are blocked. Chip–card control and allocation is made under a Super–User. The set–up of these functions is on the page ’87 PASSWORD’ chap. 4.5.11.5.
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4
4.4.3
Operation
Access/ Password Levels Allocation of Access Levels: All operating values can be controlled via password level 1, withthe exception of the following:
Screen page 10 MOULD SETUP 13 MOULD DIRECT 14 CORES
16 MOULD ... SEQUENCE 17 SEQUENCE PARAMETER 40 PRESELECT PROGRAMS
83 SETUP
85 SERVICE PAGE 87 PASSWORD 96 COMMISSIONING
183 SETUP MACHINE 852 MAINTENANCE PLAN
Function Programe option: Mould height all operating values Programme option: Core control Without release handling Switch off in end postion Time dependant Rotating core all operating values all operating values Programme option: Core pulling control and automatic operation blocked Pump splitting complete printer setting set date and time Programme option: Amendment report log Reasons for amendment Password Chip–card Confirmation of Service Page selection and operation via ”Superuser – Password” only Programme option: Dry cycle Oil Lubrication Test Check rotary table lubrication Commissioning, only in setting mode Cylinder heating Hotrunner heating remaining operating values all operating values Typing the text
upwords from Password level 2 2 2 2 2 2 2 2 2
2 2 2 3 3 3 3 5 5
2 1 1 2 2 2 4 4 5
Note: Changes can only be made on password level 2 when the machine is not operating.
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Operation
4.5
Description of the Screen Pages and their Operation
4.5.1
Screen page ”0 MAIN MENU”
4
At mains switch–on or selection of page 00, then the main menu is displayed. The machine size and type are shown on the main menu overview. The softkeys allow the display contrast to be modified or normalized. In addition it is also possible to display text in various ways as follows: Display normal, that means white text on a dark background Display inverse, that means black text on a light background Display black/white, black text on a white background
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4
4.5.2
Operation
Screen page ”1 MACHINE” – Machine Configuration
By pressing the softkey ”Machine” in the softkey line on the screen page ’0 MAIN MENU’ chap. 4.5.1, the page ’1 MACHINE’ is displayed.
The loaded software package versions are displayed, for GA, SO, automation with the SPS software and Ergocontrol software each, and the installed screw diameter. Also displayed are machine size, drive, pump, hydraulic motor and the table versions included in the software. Also, options dependent on kennbits are displayed in clear text.
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Operation
4.5.3
4
Screen page ”3 VDMA 24468” – Standardized Parameter Screen page Press Function Selection Key to select screen page ’20 PROCESS OPTIMIZATION’.
By pressing the softkey ”VDMA 24468” in the softkey line on the screen page ’20 PROCESS OPTIMIZATION’ chap. 4.5.5.1, the page ”3 VDMA 24468” is displayed.
This screen page is defined as standard (i.e. independent of the machine manufacturer) display of important parameters of operation of an injection moulding machine.
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4-27
4
Operation
Screen page ”3 VDMA 24468” – Standardized Parameter Screen page – continuation This is achieved by using units, which are independent of the type of injection moulding machine, e.g. Injection pressure:not as pressure in the hydraulics, but as specific pressure of the melt Melt cushion:
screw position not in mm, but in cm3
Screw rotation:
not as rotational speed in rev/min, but as circumferential speed in mm/s
Transfer of an injection mould to another machine as well as evaluation of the operating condition and resetting of the parameters are thus facilitated. At least partial optimisation of the injection moulding process and basic setting of important parameters after a mould change are possible with this standardised operating page. Note: Softkey ”INIT”:
INIT
The ”INIT” softkey, with which all stages not displayed on this operating page for injection, holding pressure and back pressure can be deactivated, is provided for basic setting. If the profile stages are not deactivated, the message ”Further profile data” appears in the screen page.
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4.5.4 4.5.4.1
4
Functions – Group Mould – Description of the Screen Pages Screen page ”10 MOULD SETUP” – Setting Parameters and program preselect Clamping Unit and changing of Softkey Line Press Function Selection Key to select screen page ’10 MOULD SETUP’. Screen page ’10 MOULD SETUP’ – Modular 25 up to 110
Concept only System only
Screen page ’10 MOULD SETUP’ – from Modular 125/475
Concept only System only
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4.5.4.1.1 Screen page ”10 MOULD SETUP” – changing of Softkey Line
Further
By pressing the softkey ”Further..”, the softkey line is changed
System only
4.5.4.1.2 Axis monitoring (drift monitoring) for Mould opening and closing If the PG switch “Axis monitoring switched off” on screen page ’183 SETUP MACHINE’ is deselected (see Chap. 4.5.11.2.2), then drift of the mould movement is monitored. If an undesired mould movement takes place during monitoring (e.g. from a faulty valve) an emergency stop is triggered by switching off the pump/drive. The error message “Mould axis monitoring triggered”.
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4.5.4.1.3 Setting Parameters Clamping Unit – mould speed / mould safety force For both mould open and close, 3 speeds can be set. On Concept machines the mould protection force can also be preset. Note: On System machines the mould safety force is entered on Screen Page ’120 MOULD SAFETY’ (see chap. 4.5.4.2) Example for Mould open: Mould moves from fully closed position with moderate speed V1 = 20% On reaching the trigger position at 70,0 mm speed increased to V2 = 60% On reaching the trigger position at 290,0 mm speed reduced to V3 = 30% Mould opening is stopped at the mould open position of 349,7 mm. Example of Mould closed: Mould moves from the fully open position with slow speed V1 = 30% On reaching the trigger position at 290,0 mm speed is increased to V2 = 60% On reaching the start position at 80,0 mm the closing speed is reduced to 20%
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Setting Parameters Clamping Unit – mould speed / mould safety force – continuation Note: Simultaneous mould and ejector movement With simultaneous mould and ejector movement the oil volume available for mould movement is shared. When the ejector is moving at the same time as the clamp the set values for the ejector speed and pressure are ignored. The axis given at the beginning and subsequently as a result of theparallel movement already travelled or still to be travelled, result in transition operations which express themselves in changes to the movement speed and working pressure. Even when starting and ending the parallel movements in the case of still to be travelled axis the speed will be reduced or speed peaks occur. For example, when the mould approaches its open position when travelling up, the volume discharged by the pump will be reduced and, as a consequence, also the volume of oil on the hydraulic ejector. As a result of this the ejector speed can be reduced towards the end of the mould open position. When the mould has completed its movement the hydraulic ejector can accelerate again because now the volume and pressure set on the Ergocontrol in the ’11 EJECTOR’ display mask will be provided. This reaction can be changed by varying the setting of the mold/speed profile, the hydraulic ejector starting position and the Ejector parameters. Contrary to this the mould movement will be slowed down when the hydraulic ejector travels because a proportion of the volume of oil will be branched off to the ejector cylinder. When the ejector completes its movement or tends to work sluggishly (reflected in the ejection of the parts), the mould movement will pick up speed again. In the case of set fast movements, this will have less influence than in the case of slower movements because in this case a larger volume of oil will be available in the hydraulic circuit. These factors also have an influence on the positioning accuracy of both axes and can lead to minimum fluctuations in the cycle time. Attention! The use of this option is, as a consequence, reserved only for suitable moulds, the mould and ejector movement of which can tolerate the given deviations. To be noted in particular is that with parallel mould closing and hydraulic ejector movement after the ejector movement has been completed, mould acceleration can occur which brings with it a risk of unintentional hard closing of the mould.
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4.5.4.1.4 Mould – Setting Parameters Clamping Unit – mould safety end The set value for ”Mould safety end” is set shortly before platen contact. This set value depends on the set value for the clamping force. The larger the clamping force, the largerthe setvaluefor ”Mould safety end”. Determining the set value Enter set value for clamping force. Setting of clamping force. (see chap. 5.2.2.2.2) Enter set value for ”Mould safety end” so small, that the mould does not lock during closing. The message ”Mould safety end increase” appears. Increase stepwise set value for ”Mould safety end”, until the mould locks and the message ”Mould safety end increase” does no more appear.
4.5.4.1.5 Program preselector Switch Clamping Unit – Mould safety (System machines only) The closing process is monitored by a highly sensitive mould safety sensor from ”Mould safety force Start until ”Mould safety End Stop”. Note: The mould safety curve is displayed and the set value for basic mould safety is set on screen page ’120 MOULD SAFETY’ (see chap. 4.5.4.2). PG switch ”Mould safety” switched on If the PG switch ”Mould safety” is switched on, a reference curve is recorded automatically during the first closing movement after change–over to Manual or Automatic operation. Note: The mould safety curve is displayed and the settings for mould safety monitoring, start–up mould safety and basic mould safety are set on screen page ’120 MOULD SAFETY’. Depending on the mould safety force, this reference curve is provided with an enveloping curve, which is used to monitor the closing process.
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Program preselector Switch Clamping Unit – Mould safety (System machines only) During recording the message ”saving” appears in the PG switch line (in the actual column). The closing process is then monitored after the next cycle. The message ”curve” appears in the PG switch line. In each closing process the sensor signal is compared with enveloping curve and the closing movement interrupted, if the curve is exceeded. The fault message ”Mould safety responded” appears. Attention! During recording of the reference curve the monitoring is only made via basic monitoring. Attention! The reference curve is dependent on the set speed profile for ”Mould close”. If speeds and strokes are varied, then a new reference curve have to be recorded. PG switch ”Mould safety” switched off If the PG switch ”Mould safety” is switched off, the message ”base” appears in the PG switch line. Attention! If the PG switch ”Mould safety” is switched off and a value for ”Mould safety force start” is set the displayed limit value is set, connection of the accumulator is displayed. Acc. on at a speed [mm/s]
Acc. on at a speed [mm/s]
143 Example:
a required value > limit value 143 was set for injection in this case.
Example:
a required value < limit value143 was set for injection in this case.
143
Note: The displayed limit value is dependent on the machine and cannot be operated.
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4.5.5.2
Operation
Screen page ”21 DOSING–PROFILES”
By pressing the softkey ”Dosing–Profiles” in the softkey line on the screen page ’20 PROCESS OPTIMIZATION’ chap. 4.5.5.1, the page ’21 DOSING–PROFILES’ is displayed.
Symbols Explanation
Screw retract before dosing
Direction of stages
Dosing stop
Screw retract after dosing
In this screen page a speed and dynamic pressure profile can be set via max. 6 volume– or position– dependent switch–over points after termination of ”SC back before dosing”.
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Screen page ”21 DOSING–PROFILES” – continuation Example: Screw retracts at 12 ccm/s speed to 5,7 ccm volume Step 1: Screw rotates with 654 mm/s with back pressure of 120 bar until a volume of 390,0 ccm Step 2: Screw rotates with 654 mm/s to 393 mm/s with back pressure of 120 bar to 80 bar until a volume of 447,1 ccm The screw then retracts at 20 ccm/s speed to 475,2 ccm volume as suck back. Note: Because step 3 is already switched off, the value diplayed for step 3 is not active.
4.5.5.2.1 DOSING–PROFILES – Setting Paramerters Back Pressure, Screw Rotation and Screw Stroke The rotation and back pressure profiles can be set over up to 6 volume or position dependent trigger points starting from ”screw retraction before metering”. The screw rotation can be chosen between circumferential velocity (mm/s) and revs ( U/min). – see page ’83 SETUP’ The dosing volume is given in ccm or as a stoke in mm. – see page ’83 SETUP’ chap. 4.5.11.2.1.
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DOSING–PROFILES – Setting Paramerters – continuation Retract screw before dosing The SC stroke before dosing can be set within specific limit values. lower limit:
2 mm
higher limit:
Screw stroke ”Retract screw after dosing”
Note: To prevent damage to the machine minimum screw retraction of 2 mm is required before the dosing. If an attempt is made to set a required value < 2 mm, the fault message ”lower limit exceeded” appears. If an attempt is made to set a required value > ”higher limit”, the fault message ”higher limit exceeded” appears. Enter of screw stroke for ”Retract screw before dosing” SC–Stro [mm]
4,2
Proceed by means of cursor keys or by turning the shuttle wheel to the input position in the line SC stroke. Set the new required value. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first. Note:
MAX: 167.8 MIN: 2.0
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen.
OLD: 4.2
Press the Enter key to take over the new required value; at the same time the info window is closed.
Retract screw after dosing Note: After changing the required value ”Dosing stop”, the required value for ”Screw back after dosing” is changed automatically. This means that the difference between ”Screw back after dosing” and ”Dosing stop” is maintained. If this difference is to be changed, a new required value for ”Screw back after dosing” must be set.
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DOSING–PROFILES – Setting Paramerters – continuation Speed for Screw retration Note: Screw retration after dosing on machines System with option ”GA (WA) 131 Regulated by fast–action modulating valve”: The actual screw–back speed is measured during dosing. If the setpoint value for the screw–back is less than the actual screw–back speed, then the screw–back is carried out at the actual screw–back speed, i.e. the setpoint entry for the screw–back is not effective. Setpoint values > actual screw–back speed will be effective.
4.5.5.2.2 Program preselct ”Stage” – Switch ON and OUT of Profile Stages Profile stages can be connected or disconnected by switching a switch ”Stage”. Switch OUT of Profile Stages Proceed by means of cursor keys or by turning the shuttle wheel to the stage switch, after which the stages are to be disconnected. Press Enter–Key to switch OUT the stage. Note: If the stage is switched out then the next trigger point is merged in its place for screw speed and back pressure. Therefore the values of the last end point remain unchanged until the next trigger point. Switch ON of Profile Stages Proceed by means of cursor keys or by turning the shuttle wheel to the stage switch off the stage not switched on. Press Enter–Key to switch ON the stage. Note: If the stage is switched on, the next switch–over points for speed and back pressure are faded in.
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4.5.5.2.3 DOSING–PROFILE – Shifting of Dosing Profiles Profile
4-90
Profile
With either of the arrow softkeys (left & right) the complete profile can be shifted along the trigger points.
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4.5.5.3
4
Screen page ”26 INJECTION PROFILE”
By pressing the softkey ”Injection profile” in the softkey line on the screen page ’20 PROCESS OPTIMIZATION’ chap. 4.5.5.1, the page ’21 DOSING–PROFILES’ is displayed.
Symbols Explanation Switch over from injection to holding pressure
Direction of stages
Injection start position
The injection profile can be set over 10 volume or position trigger points. Either ccm/s or mm/s can be selected for Injection Speed – see page ’83 SETUP’ chap. 4.5.11.2.1. Note: The injection start position is taken as the current screw position at that time and cannot be set.
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Screen page ”26 INJECTION PROFILE” – continuation Example: Step 1:
Inject with speed V = 200 ccm/s to volume 410 ccm
Step 2:
Continue injecting with speed V = 200 ccm/s to V = 501 ccm/s down to volume 300 ccm etc.
Note: Because step 3 is already switched off, the value diplayed for step 3 is not active. Note: Switch over from injection to holding pressure In the case of volume or position–dependent change–over to holding pressure, change–over to holding pressure takes place when the volume of 20,0 ccm is achieved. If pressure or time–dependent change–over to holding pressure is selected, the actual holding pressure volume is displayed and marked. Note: Screw stroke for switch over from injection to holding pressure The SC stroke for the change–over from injection to holding pressure can be set within specified limit values. lower limit: 0 mm higher limit: max. screw stroke Note: If an attempt is made to feed in a required value > ”higher limit”, the fault message ”higher limit exceeded” appears. Enter of screw stroke for switch over to holding pressure SC–Stro [mm]
6,5
Proceed by means of cursor keys or by turning the shuttle wheel to the input position in the line SC stroke. Set the new required value. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first. Note:
MAX: 203 MIN: 0
OLD: 6.5
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen. Press the Enter key to take over the new required value; at the same time the info window is closed.
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4.5.5.3.1 Program preselect ”Stage” – Switch ON / OUT of Profile Stages Profile stages can be connected or disconnected by switching a switch ”Stage”. Switch OUT of Profile Stages Proceed by means of cursor keys or by turning the shuttle wheel to the stage switch, after which the stages are to be disconnected. Press Enter–Key to switch OUT the stage. Note: If the stage is switched out then the next trigger point is merged in its place for injection speed. Therefore the speed value of the last end point remain unchanged until switch–over to holding pressure. Switch ON of Profile Stages Proceed by means of cursor keys or by turning the shuttle wheel to the stage switch off the stage not switched on. Press Enter–Key to switch ON the stage. Note: If the stage is switched on, the next switch–over points for injection speed are faded in.
4.5.5.3.2 INJECTION–PROFILE – Shifting of Injection Profiles Profile
Profile
With either of the arrow softkeys (left & right) the complete profile can be shifted along the trigger points. Note: The melt cushion is the minimum value that occurs during the injection and follow–up phase.
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4.5.5.4
Operation
Screen page ”27 HOLDING–PROFILE”
By pressing the softkey ”Holding profile” in the softkey line on the screen page ’20 PROCESS OPTIMIZATION’ chap. 4.5.5.1, the page ’27 HOLDING–PROFILE’ is displayed.
The injection profile can be set over 10 volume trigger points. The individual speed changes are time dependent. The height of the actual switch–over pressure is displayed as a vertical bar. Example: With switch over from injection to follow–up pressure by the switch over event the follow–up pressure is regulated from 550 bar to 350 bar within 10 sec.
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Screen page ”27 HOLDING–PROFILE” – continuation Note: The injection speed before switchover to to holding pressure must be greater than the screw advance speed arising in the holding pressure phase Because the maximaum possible screw advance speed in the holding pressure phase is limited to this value.
4.5.5.4.1 Program preselect ”Stage” – Switch ON / OUT of Profile Stages Profile stages can be connected or disconnected by switching a switch ”Stage”. Switch OUT of Profile Stages Proceed by means of cursor keys or by turning the shuttle wheel to the stage switch, after which the stages are to be disconnected. Press Enter–Key to switch OUT the stage.. Note: If the stage is switched out, then the following trigger time will follow on. Therefore after the time–out of the last holding time, the corresponding holding pressure will be maintained. Switch ON of Profile Stages Proceed by means of cursor keys or by turning the shuttle wheel to the stage switch off the stage not switched on. Press Enter–Key to switch ON the stage..
Note: If the stage is switched on, the next switch–over points for holding pressure are faded in.
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4.5.5.5
Operation
Screen page ”23 INJECTION UNIT”
By pressing the softkey ”Injection unit” in the softkey line on the screen page ’20 PROCESS OPTIMIZATION’ chap. 4.5.5.1, the page ’23 INJECTION UNIT’ is displayed.
4.5.5.5.1 INJECTION UNIT – Setting Parameters Injection Unit Speeds, Start –V2 and Stop There is a combination of two speeds available for both forward and backward movement of the injection carriage unit. In addition the starting position of V2 and the stop position of ”IU back” can be set in.
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INJECTION UNIT – Setting Parameters Injection Unit – continuation Contact Pressure The contact pressure can be set within specific limit values. Contact Pressure lower limit higher limit
40 bar 160 bar
If an attempt is made to set a required value < ”lower limit”, the fault message ”lower limit exceeded” appears. If an attempt is made to set a required value > ”higher limit”, the fault message ”higher limit exceeded” appears. Enter of Contact Pressure
Contact Pressure
50 Bar
Proceed by means of cursor keys or by turning the shuttle wheel to the input position in the line contact pressure. Set the new required value.. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first. Note:
MAX: 160 MIN: 40
OLD: 50
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen. Press the Enter key to take over the new required value; at the same time the info window is closed.
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INJECTION UNIT – Setting Parameters Injection Unit – continuation Residual pressure Demag modular 125/475 up to 350/810 and 420/810: When operating with nozzle in contact position – (PG preselector switches ”IU back before dosing” and ”IU back after dosing” switched off) – the residual nozzle sealing pressure at ”Unlock mould” is automatically limited to 5 bar. Demag modular 420/800 and 500/900 up to 2000/1800: When operating with nozzle in contact position – (PG preselector switches ”IU back before dosing” and ”IU back after dosing” switched off) – a residual nozzle sealing pressure (0–40 bar) can also be selected. When entered this residual preesure becomes active at ”Unlock mould”. Enter of Residual pressure Residual Pressure
10 Bar
Proceed by means of cursor keys or by turning the shuttle wheel to the input position in the line residual pressure. Press the Enter key and then set the new required value.
Note: MAX: 40 MIN: 0
OLD: 10
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen.
Press the Enter key to take over the new required value; at the same time the info window is closed. Delay retraction If the PG switch ”Retract before dosing” or ”Retract after dosing” is set, the injection unit moves back only after expiry of the set delay time.
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4.5.5.5.2 INJECTION UNIT – Program preselect ”Retract before/after dosing” It is possible to choose using the programme option whether to retract the carriage before or after dosing, and with or without a time delay. Note: Without selection of programme options, the carriage will not retract in Semi–Auto or automatic modes.
4.5.5.5.3 INJECTION UNIT – Manual movement of Injection Unit Press this key to switch machine to Manual mode.
Press this key to advance the carrage.
Press this key to retract the carrage.
Note: The carriage can be retracted as far as the Injection unit stop in Manual mode, by pressing the corresponding function key. Pressing this function key again after the programmed stop position has been reached, allows the operator to retract the carriage to the mechanical end stop of the machine.
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4.5.5.5.4 INJECTION UNIT – Switch ”Set zero datum” Determining the carriage set–up: In Set–up mode, the carriage will move forward until the nozzle touches the register ring and carriage pressure is maintained.
Press this key to switch machine to ”Set–up mode” .
Press this key to advance the carrage.
Note: As soon as this position has been reached, the current position of the carriage with ”Set zero datum” is stored.
Set zero datum
Proceed by means of cursor keys or by turning the shuttle wheel to the switch ”Set zero datum”. Press the Enter–key to confirm the Reference position. Note: Injection can only then occur at this carriage position and with the set carriage pressure.
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4.5.5.6
4
Screen page ”24 MWE” – MWE Scanner
By pressing the softkey ”MWE” in the softkey line on the screen page ’20 PROCESS OPTIMIZATION’ chap. 4.5.5.1, the page ’24 MWE’ is displayed.
4.5.5.6.1 MWE Scanner – general The MWE unit allows scanning measurements to be made on the following parameters: 2 Mould cavity pressure profiles Injection profile Screw position Melt temperature The scan period starts with injection after a selectable start delay until end holding pressure after a selectable stop delay, and is displayed graphically.
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4.5.5.6.2 MWE Scanner – Profile Representation and Changing of Softkey Line
By pressing the softkey ”Section” in the softkey line on the screen page ’24 MWE’ , the softkey line is changed ( new softkey line see following picture).
Description of the page ’24 MWE’: Simultaneous graphical representation of the profiles: A maximum of 4 actual profiles OR 1 Actual profile with its accompanying Master Profile These options can be selected throughout the programme pre–selection page.
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4.5.5.6.3 MWE Scanner – Softkey Functions
”Selection”: When this softkey is pressed, the sampling window (min 50 values max 400 values) indicated by the integral–cursor is zoomed to fill the display. Below the time scale, the position of the sample window is represented on the whole curve with darker bars. ”Integral Start/Stop”: Using the integral–cursor the operator can select a sampling window from the total profile in order to monitor the integral. Note: After pressing softkey ”Integral Start” or ”Integral Stop”, the corresponding integral–cursor can be varied by turning of the shuttle wheel ”Write Lock”: Profile Write: In the Profile write mode, profiles are generated and displayed for every injection stroke. Profile Stop: In the Profile stop mode, profile are still generated ,but they are not displayed until the Profile Write is again switched on. So it is possible to give an opinion on the actual profile of one injection stroke during running production. Note: After switching to ”Profile Write”, the momentary actual profiles are displayed straight away. Note:
Profi le stop
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The respective operating mode is displayed in the bottom left– hand corner of the screen page.
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MWE Scanner – Softkey Functions – continuation
”Complete curve”: This softkey displays the total injection phase. ”Value Curs”: The data cursor allows the operator to move to any of the 50–400 readings within the profile window, and thus read off the absolute value for that particular point. ”Master”: Those profiles that have been selected in the page ’25 MWE CONFIGURATION’ can be converted to a master profile using this softkey The Master profile is made up of the current profile for the particular parameter.
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4.5.5.7
4
Screen page ”25 MWE CONFIGURATION” – MWE scanner – Parameter selection / – settings
By pressing the softkey ”MWE confign.” in the softkey line on the screen page ’24 MWE’ chap. 4.5.5.6, the page ’25 MWE CONFIGURATION’ is displayed.
This page allows the set–up of start and stop delay time and the selection of the 4 parameters to be scanned. Characteristics Sensitivity and Diameter (ejector–pin diameter) There are therefore input fields for the characteristics (sensitivity, ejector–pin diameter) of the pressure sensor; either quartz piezo– electric or strain–gauge.
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Screen page ”25 MWE CONFIGURATION” – MWE scanner – Parameter selection / – settings – continuation Scaling of Profiles For every selected profile a vertical signal scale min/max can be entered. Note: The scales of the selected profiles are displayed automatically on the page ’24 MWE’ chap. 4.5.5.6 Selection of Profile The profile is selected by input of the required profile number (1...4) in the profile column. Example:
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Profiles for injection pressure (profile 1), mould cavity pressure 1 (profile 2) and SC stroke (profile 3) were selected in this case.
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4.5.5.8
4
Screen page ”28 INTRUSION” – Intrusion and Remove cold–slug
By pressing the softkey ”Intrusion” in the softkey line on the screen page ’23 INJECTION UNIT’ chap. 4.5.5.5, the page ’28 INTRUSION’ is displayed.
Intrusion If the PG switch ”Intrusion” is switched on, the screw is rotating during the selected intrusion time to intrude material into the mould before injection. Both pressure and rotation speed can be set separately. Remove cold–slug If it is necessary to remove the cold slug from the nozzle before injection, the appropriate selection can be made from the programme options together with a time when the slug is to be removed by rotation of the screw. Both pressure and rotation speed can be set separately. Note: This operation occurs before the injection unit moves forward.
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4.5.6 4.5.6.1
Operation
Functions – Group Temperatures – Description of the Screen Pages Screen page ”30 TEMPERATURES” – Setting Parameters Barrel and Oil Temperatures, Cold start protection as well as Program Selectors Press Function Selection Key to select screen page ’30 TEMPERATURES’.
4.5.6.1.1 Temperatures – Switching ON and OFF of barrel heating
ON
The barrel heating has separate switches on the Ergocontrol console for switching it on and off.
OFF
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4.5.6.1.2 Temperatures – Setting Parameters Barrel and Oil Temperatures, Cold start protection and Graphical representation Each heating zone has a set value, an actual value, positive and negative tolerances, and an actual percent of utilization. Graphical representation desired–/ actual value The barrel temperatures are represented as a figure with set and actual values for each zones shown as bars. Number of jacket heater zones A differing number of jacket heater zones are active, depending on size of injection unit. Number of jacket heater zones
Injection unit IU 80 IU 120 IU 200 IU 310 IU 430 IU 600 smallest a. medium Cylinder
3
IU 600 largest Cylinder
4
IU 320 IU 440 IU 840 IU 1450 IU 2300
4
IU 3300 IU 6400 IU 9500 – j95 + j110 (20D)
5
IU 9500 – j110 (25D) + j130
6
IU 11500
6
IU 16000
6
Max. permitted plasticising cylinder temperatures Depending of machine type following maximal plasticising cylinder temperatures are permitted. Machine type
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max. perm. cyl.–temperat. C
F
Demag modular 25 up to 350/810 and 420/810
450
842
Demag modular 420/800 and 500/900 up to 2000/1800
400
752
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Temperatures – Setting Parameters Barrel and Oil Temperatures, Cold start protection and Graphical representation – continuation Note: Controller optimisation Controller parameters are automatically adjusted to suit the characteristics of the attached cylinder zone. See chap. 4.5.12.3 ”Set up control”. Note: Demag modular 25 up to 420/810: If the temperature set value of the shell heating zones is higher than 400C, the injection pressure will automatically be limited, when the smallest plasticising cylinder is installed. Switching OFF of Heating zones and Deactivating of Temperature reduction (Set temperature = 0) Note: If a value of zero is set for a particular zone, then that zone is omitted from the monitoring process. If a value of zero is set for Temperature reduction, then the Temperature reduction is deactivated, i.e. with the PG switch ”temperature reduction” switched on there is no regulation to temperature reduction. Appropriate temperature tolerances Appropriate positive and negative tolerances can be set quite independently, and separately for each zone. Cold start protection When the tolerance band is re–entered then screw rotation is prevented for the set start–up time to allow the heat to penetrate the cold melt. Attention! If the setpoint temperature is not selected to correspond to the processing temperature of the specific plastic, or the start–up delay is too short and the lower tolerance of the tolerance band has been set too low, then there may be damage to the screw or the tip of the screw. The cold start protection has to be at least 15 – 20 minutes and the negative tolerance of the tolerance band has to be in maximal – 20C.
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Temperatures – Setting Parameters Barrel and Oil Temperatures, Cold start protection and Graphical representation – continuation Oil Temperature The oil temperature can be set within specific limit values. lower limit: higher limit:
40 C 50 C
Note: If an attempt is made to set a required value < ”lower limit”, the fault message ”lower limit exceeded” appears. If an attempt is made to set a required value > ”higher limit”, the fault message ”higher limit exceeded” appears. FEED 45 ........ 45 ........ 10 ....... 10 ........
OIL 50 50 10 10
Enter of Oil temperature Proceed by means of cursor keys or by turning the shuttle wheel to the required input position in column oil. Set the new required value. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first. Note:
MAX: 50 MIN: 40
OLD: 45
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen.
Press the Enter key to take over the new required value; at the same time the info window is closed. Tol +/ Tol– for oil temperature Note: The tolerances for the oil temperature are fixed values and therefore cannot be operated.
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4.5.6.1.3 Temperatures – Program preselect ”Heating monitoring”, ”Temperature reduction”, ”Oil prewarming” and ”Control by wire breaks” Program preselect ”Heating monitoring” Positive tolerance Should the temperature rise above the upper tolerance during Automatic operation, then the temperature deviation alarm is displayed and the heating completely switched off. Note: The error message can only be reset after all the heating zones have cooled down and are within the positive tolerance band again, by switching off and then resetting the program switch ”Heating monitoring”. Negative tolerance When the temperature sinks to below the lower tolerance, then the machine continues until it reaches the base position. Besides the fault message ”Temperature deviation” is displayed. Note: The error message can be reset by switching off and then resetting the program switch ”Heating monitoring”. Sensor–/ cable break An open circuit thermocouple will cause a temperature reading of 704C to be displayed, in which case the machine continues until the base position. Program preselect ”Temperature reduction” The soak temperature is the same for all barrel heating zones as well as mould heating zone1 and 2 (page ’33 MOULD HEATING’, see chap. 4.5.6.4) where the normal set value is greater than the set soak temperature; otherwise the set value applies. By setting of PG–switch ”TEMPERATURE REDUCTION” in set– up and manual mode the soak temperature can be applied not only by the automatic switch–off program, but also manually. Note: In semi–automatic or fully automatic mode, the program switch ”Temperature reduction” is out of action. In ofher words, the temperature reduction is made exclusively through the automatic switch–off program.
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Temperatures – Program preselect ”Heating monitoring”, ”Temperature reduction”, ”Oil prewarming” and ”Control by wire breaks” – continuation Program preselect ”Oil prewarming” Oil pre–heating can be selected to come on with the pump motor if required. Note: However no hydraulic movement is possible when it is in action. Note: In the multi machines the oil pre–heating is automatically switched on when the start key is pressed, if the oil temperature is below 35C. Program preselect ”Control by wire breaks” An open circuit thermocouple in a heating zone will activate the PG–switch ”Control by wire breaks”. In this case a constant value is sent to the heating zone. This constant value is automatically determined when the temperature remains inside the set tolerances for a defined time. Note: The function ”Control by wire breaks” is only possible when this constant value has been determined.
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Temperatures – Program preselect ”Heating monitoring”, ”Temperature reduction”, ”Oil prewarming”, ”Control by wire breaks” and ”Synchronous heating” – continuation ”Synchronous heating” program switch If the ”synchronous heating” program switch has been set, the different jacket heating zones will be heated up to the same extent to ensure that they achieve their desired values at almost the same point in time. Note: In this way damage to thermo–sensitive materials is prevented as a result of excessively long local heating up. The heating up operation under these circumstances is determined solely by the slowest zone which takes slightly longer in this mode of operation. Without the synchronous heating function the different zones will be heated up at different speeds due to their physical parameters. Synchronous heating up is started: when the cylinder heating system is switched on with turned on program switch or the program switch is turned off and on with switched on cylinder heating system. The heating operation continues until all jacket heating zones have exceeded their lower tolerance range. Not taken into consideration are zones which are switched off by setting the desired value to zero. Note: The synchronous heating up system will be interrupted and switched off immediately when the program switch is turned off when the tolerance range is attained in all zones. Any changes in parameters (temperatures and tolerances) will not lead to function switch off as long as at least one heating band is below the tolerance range when the parameters are altered.
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4.5.6.2
4
Screen page ”31 HOT RUNNER 1–16” and ”32 HOT RUNNER 17–32 ”– Hot Runner – Temperatures
By pressing the softkey ”Hot run. 1–16” in the softkey line on the screen page ’30 TEMPERATURES’ chap. 4.5.6.1, the page ’31 HOT RUNNER1–16’ is displayed.
Note: By pressing the softkey ”Hot run. 17–32” in the softkey line on the screen page ’31 HOT RUNNER1–16’ chap. 4.5.6.2, the page ’32 HOT RUNNER17–32’ is displayed.
4.5.6.2.1 Temperatures – Switching ON and OFF of hot runner heating as well as start–up characteristic Switching ON and OFF of hot runner heating ON
The Hot Runner heating is switched on and off using seperate switches ”Mould heating” in the Ergocontrol.
OFF
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Temperatures – Switching ON and OFF of hot runner heating as well as start–up characteristic – continuation Start–up
characteristic
As soon as the system is activated, after 5 minutes the temperature is regulated at the start–up value. Note: Hot runners whose set temperature is less than the soft start temperature are controlled directly to the set temperature. Boostoffset = 0: After a further delay of 2 minutes the start–up temperature is regulated to the normal set value. Note: If the set temperature is not reached by all zones within the preset heating–up time (2 + 5 min), the system waits for the last zone and only then controls to the set temperature. Boostoffset > 0 and PG–switch ”Boost” set After a time of 2 minutes the boost time is started and the soft start temperature is no longer used. The system controls to boost temp. = zone set temp. + boost offset and held until the end of the preset boost time. Note: If the soft start temperature is not reached by all zones within the preset heating–up time (2 + 5 min), the system waits for the last zone and only then controls to the boost temperature and starts the boost time. Note: After the boost time has elapsed the system controls to the selected set temperature.
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4.5.6.2.2 Hot Runner – Lettering of Hot Runners Any desired text of up to 11 characters can be entered in the first column for each hot runner zone. Note: The number of the hot runner zone can not be altered.
Typing the text Move the cursor to the input line
Press the ”ABC” key on the console to activate all the ASCII character keys. During typing the keys for Manual operation are blocked.
”Shift”
”ABC”
Use the shift key for capitals.
End a line with the E=Enter key
Use the Clear key to delete. The rest of the line is then shuffled left.
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4.5.6.2.3 Temperatures – Setting ”Hot runner temp.”, ”Soft start temp.”, ”Temp. reduction” and ”Boost temperature” and Boost time settings. Boost time remaining, ”Prop. % Hand” and ”Slave” The screen page includes the following set values for each heating zone: operating temperature, boost temperature, standby temperature, plus and minus tolerances and percentage power for open loop control. There are also actual value displays of temperature and percentage power consumption. The page also includes set values for soft start temperature and boost time, a display of the remaining boost time and a slave entry for slaving a hot runner to another zone. If a hot runner is not optimised or is just being optimised, the appropriate symbol appears on the hot runner in question, (see Kap. 4.5.12.3.1) Symbol for “running optimation” Symbol for “not optimised” Set/actual value graphics The set and actual values for each zone are displayed as bars. The wide bar shows the actual value and the narrow green bar shows the range of deviation from the set value. The upright stripe is the set value. Various colours indicate the status of each heating zone: green: Temperature within tolerance blue:
Under temperature
red:
Over temperature
Number of Hotrunners Depending on machine type it is possible to have closed loop hot runner control with 1, 2, 3, 5, 8, 9, 12, 16, 24 or 32 controls. Machine type
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Number of Hotrunners 1
2
3
5
8
9
12 16 24 32
Demag modular 25–350/810 and 420/810
X
X
X
X
X
X
X
X
X
–
Demag modular 420/800 and 500/900–2000/1800
X
X
X
X
X
X
X
X
X
X
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Temperatures – Setting ”Hot runner temp.”, ”Soft start temp.”, ”Temp. reduction” and ”Boost temperature” and Boost time settings. Boost time remaining, ”Prop. % Hand” and ”Slave” Switching OFF of Heating zones and Deactivating of Temperature reduction (Set temperature = 0) Note: If a value of zero is set for a particular zone, then that zone is omitted from the monitoring process. If a value of zero is set for Temperature reduction, then the Temperature reduction is deactivated, i.e. when the PG switch ”Temp. reduction” is switched on no control is made to Temperature reduction. Tolerances for temperatures The default tolerances can be entered globally for all zones or each zone can be set differently. Note: The heating and tolerance monitoring functions are the same as for the barrel (see chap. 4.5.6.1.2). Regulator/controller operation (duty cycle % manual > 0) Hot runners can be either be controlled or set by ”Hand” – default percentages. (The adjustment function precedes control i.e. when a value is entered ED % Hand is set at >0). Note: Controller optimisation Controller parameters are automatically adjusted to suit the characteristics of the attached hot runner. See chap. 4.5.12.3.1 ”Set up control”. Start–up Temperature The start–up temperature effects all hot runner zones whose set valves are larger than the start–up temperature.
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Temperatures – Setting ”Hot runner temp.”, ”Soft start temp.”, ”Temp. reduction” and ”Boost temperature” and Boost time settings. Boost time remaining, ”Prop. % Hand” and ”Slave” Temperature reduction The active hot runner zones can be cooled to a pre–set temperature as soon as the zones are in control operation (above the start up temperature). Note: The temperature reduction effects all hot runner zones whose set valves are larger than the temperature reduction. The temperature reduction can be activated seperately from the ”automatic” shut–down by using the PG switch ”Tem. reduction”. Boost– temperature, –time and –remainingtime Should the PG switch ”Boost” be switch on then the pre–set Boost temperature effects all hot runner zones. The zones are controlled to the boost temperature and kept there until the end of the boost time (1–99 minutes). The remaining boost time is indicated. After the boost time is ended the PG switch ”Boost” is automatically reset. Note: If the soft start temperature is still active, the boost time does not start until the end of the soft start phase. Hook The selected hot runner can be assigned to another hot runner by input of the hot runner No. in the ”Hook” column.
ED % Hand Act. Hook
Note: The regulator or controller operation of the hot runner then takes place with actual % ”on time” of the assigned hot runner. Example:
Zone Zone Zone Zone
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0.0 0.0 0.0 0.0
14.5 0.0 14.5 22.6
0 0 1 0
Hot runner 3 was assigned to hot runner 1, i.e. the hot runner 3 is controlled with the actual ”on time” % of hot runner 1.
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4.5.6.2.4 Hot Runner – Program preselector Switches ”Heating monitoring”, ”Boost”, ”Startup protect”, ”Startup protect”, ”Set control load” and ”Synchronous heating” PG switch ”Heating monitoring” If the PG switch ”Heating monitoring” is switched on in screen page ’30 TEMPERATURES’, the hot runner temperatures are also monitored. Note: The heating monitoring functionality is extend. to the cylinder heating, (see chap. 4.5.6.1.3). PG switch ”Boost” If the PG switch ”Boost temperature” is switched on, the required temperatures are increased by the preselected boost temperature and held there transiently for (15 min). pre–heating temp. = appropriate set tem. + Boostoffset Note: After the boost time is ended the system controls to the set temperatures again. Note: The melt can be re–melted by the transient temperature increase, e.g. in the case of frozen–off hot runner nozzles in the sprue area. In addition the insertion time of moulds at the start of production is shortened; because the processcan be stabilised more quickly. PG switch ”Startup protect” If the PG switch ”Startup protect” is switched on, the cycle can not start until the boost time has elapsed.
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Hot Runner – Program preselector Switches ”Heating monitoring”, ”Boost”, ”Startup protect”, ”Startup protect”, ”Set control load” and ”Synchronous heating” – continuation PG switch ”Temperature reduction” The temperature reduction effects all hot runner zones whose set valves are larger than the temperature reduction. The temperature reduction can be activated seperately from the ”automatic” shut–down by using the PG switch ”Tem. reduction”. Note: In semi–automatic or fully automatic mode, the PG switch ”Temperature reduction” is out of action. In ofher words, the temperature reduction is made exclusively through the automatic switch– off program. PG switch ”Synchronous heating” If the PG switch ”Synchronous heating” is selected, all zones are heated up at the speed of the slowest heating zone. PG switch ”Set control load” An open circuit thermocouple in a heating zone will activate the PG–switch ”Control by wire breaks”. In this case a constant value is sent to the heating zone. This constant value is automatically determined when the temperature remains inside the set tolerances for a defined time. Note: The function ”Control by wire breaks” is only possible when this constant value has been determined.
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Hot Runner – Program preselector Switches ”Heating monitoring”, ”Boost”, ”Startup protect”, ”Startup protect”, ”Set control load” and ”Synchronous heating” – continuation Example of the functions:
Hot Runner 1: Controlling and displaying % power Hot Runner 2: Open circuit sensor, now uses previous % value to continue open–loop Hot Runner 3: Switched off (zero set value) Hot Runner 4: No thermocouple, heating on % value open–loop
Note: Further informations see interface description chap. 5.4.9 ”ZE 266 – ZE 279 Hot Runner Control”.
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4.5.6.3
Screen page ”38 CONDITIONING UNIT”
By pressing the softkey ”Condit unit” in the softkey line on the screen page ’30 TEMPERATURES’ chap. 4.5.6.1, the page ’38 CONDITIONING UNIT’ is displayed.
Interfacetyp
only by CAN–BUS
This page is for setting the integrated mould temperature circuits. The temperature control unit is connected via a CAN–bus or a TTY interface. The type of interface used (CAN or TTY) is displayed with the corresponding address. The temperature control unit can also be activated through the ”SWITCH–ON PROGRAMME” by actuating the PG switches ”SWITCH–ON PROGRAMME FOR CIRCUIT 1 / CIRCUIT 2”, if ZE 440 is part of the available equipment (see Chap 4.5.7.2).
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Screen page ”38 CONDITIONING UNIT” – continuation Conditioning Unit via CAN–BUS Any combination of the two circuits can be used. Conditioning Unit via TTY–Interface Six tempering unit circuits are available with same function in a total of 3 displays. The different displays (Temp. unit 1, 2; Temp. 3, 4; Temp. unit 5, 6) can be selected by soft key. Setting the mould temperature circuits: Program switch circuit Data exchange between Ergocontrol and the tempering circuit is only assured when the tempering circuit is online and the program switch has been set. If the tempering circuit is offline and the program is set then the pertinent parameters in the ’38 CONDITIONING UNIT’ display mask will be concealed by an offline message (see example channel 2) and a machine alarm ”tempering unit x irregularity” will be generated. If the program switch is not set the lacking connection to the tempering circuit will be irrelevant for the machine. In this case no fault message will be given. Set: Set value, max. 200C Attention! Observe the instructions of the tempering unit manufacturer. Note: Soak temperature, max. 80C; Soak occurs when the programme option is selected. Tolerance + / –: Tolerance band for actual values Note: TTY Since the pretransmission of the tolerance is not supported by the TTY tempering unit interface, the tolerance evaluation is independent of the tempering unit in Ergocontrol. As a result the tolerance values in the tempering unit and Ergocontrol must be identical as a result.
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Screen page ”38 CONDITIONING UNIT” – continuation Lowering temperature: The lowering temperature max. 90°C; the temperature is lowered when the ”lowering temperature regulation” mode of operation is selected through the scroll bar menu. Note: TTY Since transfer of the standby temperature is not supported by TTY temperature controllers, this value must be entered on the temperature control unit and is not present on the Ergocontrol. Resetting mode of operation: mode of operation to be selected through the scroll bar menu. Attention! Observe the instructions of the tempering unit manufacturer because not all the modes of operation are supported by all tempering units. Depending of the interfacetyp are the following operating modes possible: CAN–BUS
TTY
Detail description of the function from the integrated Conditioning Unit see Manual ”Conditioning Unit”.
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Screen page ”38 CONDITIONING UNIT” – continuation Measurement signals from the mould temperature controller per cycle: Act : Actual Temperature in C Current mode of operation: the actual mode of operation % H / C : Percentage of heating to cooling Status : Show the current status for each cycle. Faults : Specific fault messages for each cycle. When these occur the Ergocontrol alarm buffer reads mould temperature fault 1 (2). Hinweis: Further informations see interface description chap. 5.4.26 ”ZE 556 Interface 20 mA for Temperature Control Units”.
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4.5.6.4
Operation
Screen page ”33 MOULD HEATING”
By pressing the softkey ”Mould heating” in the softkey line on the screen page ’30 TEMPERATURES’ chap. 4.5.6.1, the page ’33 MOULD HEATING’ is displayed.
ON OFF
Switching ON and OFF of mould heating The mould heating is switched on and off using seperate switches in the Ergocontrol. Mould Heating Zone and Circuit The screen page includes as an option temperature displays for mould zones 1 and 2 as well as additional controllers (3 point regulators: heating / off / cooling) for external temperature control zones Circuit 1 and 2 / 3 / 4.
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Screen page ”33 MOULD HEATING” – continuation Heating monitoring The heating monitoring functionality is extend. to the cylinder heating, (see chap. 4.5.6.1.3). Controller optimisation Controller parameters are automatically adjusted to suit the characteristics of the attached mould zone. Note: Further informations see interface description chap. 5.4.23 ZE 554, ZE 555 ”interface for Temperature Indication Mould” and chap. 5.4.24 ZE 550, ZE 551 ”Interface for Temperature Control Units”.
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4.5.7 Functions – Group Program – Description of the Screen Pages 4.5.7.1 Screen page ”40 PRESELECT PROGRAMS” 4.5.7.1.1 Screen page ”40 PRESELECT PROGRAMS” – Program Preselect I O
Press Function Selection Key to select screen page ’40 PRESELECT PROGRAMS’.
This page shows an overview of the ON/OFF function controls. These programme switches can be switched ON and OFF using the E=Enter key. Certain input fields shown as PG... are not yet allocated functions and are reserved for future and special functions. Note: Programme options ”Core pulling control” and Automatic operation”can only be operated from password level 2 and above.
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4.5.7.1.2 Screen page ”40 PRESELECT PROGRAMS” – Changing of Softkey Line
By pressing the softkey ”Switch ON program” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’, the softkey line is changed ( new softkey line see following picture).
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4.5.7.2
Operation
Screen page ”41 SWITCH–ON PROGRAM” – Programming of Switching ON for Oil prewarming, Cylinder heating, Socket combination as well as Mould temperature
By pressing the softkey ”Switch on Program” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’ chap. 4.5.7.1.1, the page ’41 SWITCH–ON PROGRAM’ is displayed.
By pressing the softkey ”Switch ON program” the page ’41 SWITCH– ON PROGRAM’ is displayed.
The switch– on programme can activate the pump and oil preheating, socket combination, barrel and mould temperatures at a different time on any particular day of the week, or at any particular time and date.
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Screen page ”41 SWITCH–ON PROGRAM” – continuation Manual Switch ON / OFF of socket combination By actuating the softkey ”switch on socket” or ”switch off socket” the socket combination can be switched independetly from the switch–on program. switch on switch off socket socket
Setting up for the switch–on programme: Mains switch is ON Pump is OFF Heater switch is off. Select the switch–on program per day or for a specific date. If date is selected ensure the desired switch–on time and date are typed–in. Enter of Switch–ON parameter: If day is selected ensure the desired switch–on time is typed–in.
Switch–on program Daily Date
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position. 11.01.99 05:15 Typ the desired value for date and time. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first. Press the Enter–key to confirm the typed value. when Switch–ON via day and time (PG–switch ”Daily” is switch on)
Mo
05 : 30
Cylinder– heating Mo
Do
05 : 30
Do
Oil prewarming
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position.
Press the Enter–key. Actuate the corresponding number for the required day or period in the number block. The selected day or period appears at the input position.
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Screen page ”41 SWITCH–ON PROGRAM” – continuation
Press Enter–key to confirm the selected day or time period.
Mo
05 : 30
Cylinder– heating Mo
Do
05 : 30
Do
Oil prewarming
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position. Press the Enter–key and then typ the desired time. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first.
Press the Enter–key to confirm the selected time.
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4.5.7.3
4
Screen page ”42 STARTUP PROGRAM”
By pressing the softkey ”Switch on Program” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’ chap. 4.5.7.1.1, the softkey line is changed.
By pressing the softkey ”Startup program” the page ’42 STARTUP PROGRAM’ is displayed.
The moulding machine can through a selection of parameters be started–up in 3 stages. The third stage corresponds to normal operation. The number of cycles for each start–up stage can be set. Note: The start–up programme can run through any combination of stages 1 and 2.
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Screen page ”42 STARTUP PROGRAM” – continuation Stage 1 Set 5 1.00
Stage 2 Set
Switch in / out of stages Each stages can be switched in or out.
3 1.00 Note: Whichever stage is currently active, a message will be shown in inverse text on the display to indicate stage 1 or 2. Example:
Stage 2 was selected for start–up in this case and the stage is currently active.
Program preselect ”Startup program” The programme preselect option for start–up programme must be selected. Program preselect ”Startup program reset” The programme preselect option for reset of the start–up program must be set for each new start of the programme.
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4.5.7.4
4
Screen page ”43 PURGING PROGRAM”
By pressing the softkey ”Switch ON program” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’ chap. 4.5.7.1.1, the softkey line is changed.
By pressing the softkey ”Purging program”, the page ’43 PURGING PROGRAM’ is displayed.
There are 3 ways to initiate the purge programme: Purge by time and date Purge by machine alarm or counter (daily, hourly–active, monitoring from... to...) Note: Program only becomes active when the time entered is reached. Purge by manual softkey
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Screen page ”43 PURGING PROGRAM” – continuation Program start Purging starts at the end of the switch–off delay if the programme option has been selected. Note: The switch–off delay is only active if the programme option for cycle control has been selected. Manual Start of Purging program
Manual– Purge
In semi–automatic and automatic modes the program can be started independently from the programmed Switch–on Program by actuating the “Manual– purge” softkey. Program sequence At the start of the purge the material hopper is closed off, then the injection unit retracts to a set position with the mould open (only with ZE 441 ”switch on–off program with closing of material feed). The purging and dosing follow the setting of the two processes to the number of purges indicated. Note: Program sequence on Mould with Cores: If the mould is fitted with core pulling, and the cores are unable to withdraw due to some problem, then the mould will not open. In this case the purging will proceed with the mould closed. Setting parameter ”Purge delay” If the cycle is to be properly completed – (mould open, ejector forward and back) – Then the time for ”Purge delay” must beselected so that the cycle can be safely completed (approx. to cycle time). Note: When ”Purge delay” = O, the cycle is interrupted as soon as the criteria for switch off is reached.
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4.5.7.5
4
Screen page ”44 SWITCH OFF MATRIX”
By pressing the softkey ”Switch ON program” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’ chap. 4.5.7.1.1, the softkey line is changed.
By pressing the softkey ”Switch OFF ’44 SWITCH OFF MATRIX’ is displayed.
matrix”
the
page
The operator can program whether a machine alarm, or counter value will switch off the pump, barrel and mould heating, or plugged–in external devices; and in which combination.
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Screen page ”44 SWITCH OFF MATRIX” – continuation The programme option for cycle control must be selected so that the switch of delay time is activated. If the barrel heating is to drop to soak temperature, the Programme option should not be activated for barrel temperature. The soak temperature should be typed into the page ’30 TEMPERATURES’ chap. 4.5.6.1 and the corresponding programme option for soak temperature should be selected.
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4.5.7.6
4
Screen page ”45 MOULD CATALOGUE”
By pressing the softkey ”Mould Catalogue” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’ chap. 4.5.7.1.1, the page ’45 MOULD CATALOGUE’ is displayed.
Setting programs can be save to, and load from disks using this page. It is also possible to format disks directly at the NC4 console by selecting the ”Tools” softkey. Use 3.5 inch disks, High–Density (HD), 1,44 MB–formatted, as specified in chap. 4.2.13 disk Drive. Softkey ”Page Fwd/Back”: With actuation of the sofkey change–over is effected between input mode (e.g. input of a new mould PG No.) and page–changing mode (e.g. selection of a data record). Note: The page ’45 MOULD CATALOGUE’ requires password access level 2 or above.
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4.5.7.6.1 To format a disk
By pressing the softkey ”Disk Tools” in the softkey line on the screen page ’45 MOULD CATALOGUE’ chap. 4.5.7.6, the softkey line is changed.
Attention! Formatting a used disk will destroy the original data. Insert a disk into the drive. Then press soft key ”Disk Tools”. Select ”Format 1.44Mb”. The disk will be formated automatically. Note: During formatting it is not permitted taking the disk out of the drive. Note: Formatting can only be executed, when the machine is not executing any functions.
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4.5.7.6.2 Saving Settings Selection of Saving Comlete Data or Robot Data Before storage it can be selected whether the complete data or only the robot data are to be stored.
By pressing the softkey ”Component Selection” in the softkey line on the screen page ’45 MOULD CATALOGUE’ chap. 4.5.7.6 , the softkey line is changed.
Robot–Data Select the softkey ”Robot Data”. A robot symbol will be placed next to the mould program number and a filter is activated which allows only the robot data to be edited. The Robot set – up programs which have been saved are displayed marked with a robot symbol. If the softkey ”Complete date” is actuated, the complete setting data including the robot data are stored. The robot symbol possibly displayed behind the mould PG No. disappears.
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Saving Settings – continuation
Find the appropriate disk and push it home into the floppy drive. To save the settings on disk under a chosen mould program number, type the number in the field and press E=Enter. In the description field type–in a meaningful identifying text for the settings and again press E=Enter. Then press the softkey save settings. Note: When the mould program is already existing under the same mould program number, then the message ”already exist–do you want to overwrite ?” appears. Over– Write
Cancel
By pressing the appropiate softkey the mould program will be overwritten or saving will be canceled. The settings will be save on the disk as a file under the chosen mould program number together with the identification text. Note: When the storage is complete the text message appears saying the mould program has been stored. Always label the disk clearly for fast re–loading.
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4.5.7.6.3 Reading a disk
By pressing the softkey ”Disk Tools” in the softkey line on the screen page ’45 MOULD CATALOGUE’ chap. 4.5.7.6, the softkey line is changed.
Find the appropriate disk and push it home into the floppy drive. Press the softkey ”Disk Tools”, Then press the softkey ”Read verify” The settings available on the disk will be listed. After reading in a data record disk the still free memory of the disk is shown in the display. Note: If the mould program disk is inserted in the floppy drive when the screen page ’45 MOULD CATALOGUE’ chap. 4.5.7.6 is activated, a list of setup programs mill be displayed. If the disk is changed after reading in a disk, the new disk content should be read in again by actuation of the softkey ”Read verify”.
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4.5.7.6.4 Loading settings
Select Page using the ”Page/Input” softkey. Use the cursor keys to move through the mould catalogue. Then when the desired setting program number is highlighted, press the load settings softkey.The settings will copied from the disk into the Ergocontrol. The display will show the New current mould setting program number. Note: If the selected data record is not in agreement with component selection, the fault message ”Data set not compatible with set–up” appears. After the corresponding component selection the selected data record can be loaded. Note: If the disk contains more than 15 mould setting programs, the arrow keys Increment / Decrement can be used to page back and forwards
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Loading settings – continuation Note: Loading mould setting data is only possible, when the machine is not executing any functions. Attention! Mould data records from other machines should be checked and must be adapted if necessary.
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4.5.7.6.5 Delete Settings
Select Page using the ”Page/Input” softkey. Use the cursor keys to move through the mould catalogue. Then when the desired setting program number is highlighted, press the delete settings softkey. The display will show the confirmation question, ”Delete settings ?” If the settings are to be deleted then press the delete softkey again. If the settings are not to be deleted then press the cancel softkey. Note: After loading settings into the machine, the display shows the remaining free memory on the disk. The maximum memory taken by a machine with full automation components is about 20 Kbytes.
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Screen page ”99 ERGOSTART” – Machine pre–setting
Purpose With data on component geometry, shot weight and material type already specified, the Ergostart software program provides the operator with all the machine setting data required torun the preliminary moulding cycle. Setting data for the injection unit can be altered prior to data transfer to meet individualrequirements. Advantages –
Less time is needed for machine and mould optimisation with new moulds.
–
Incorrect settings and hence damage to the mould are prevented.
Note: The program is suitable for standard injection moulded parts. The program does not allow for special processes such as the gas injection process, 2–colour / 2–component moulding, in–mould decoration, fast injection with accumulator etc.
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4.5.7.7.1 Screen page selection, input sequence and softkey functions
By pressing the softkey ”Ergostart” in the softkey line on the screen page ’40 PRESELECT PROGRAMS’ chap. 4.5.7.1.1, the page ’99 ERGOSTART’ is displayed.
Once the ”Ergostart” softkey has been actuated, data on component geometry (see chap. 4.5.7.7.2.3) and shot weigh (see chap. 4.5.7.7.2.2) can be entered on screen page ’99 ERGOSTART’ and the material can be selected (see chap. 4.5.7.7.2.1). The program then comes up automatically with appropriate settings. Input parameters and, if required, the recommended setting parameters can be selected using thecursor and entered or altered via the ten key keyboard.
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Screen page selection, input sequence and softkey functions – continued Then each set value is confirmed using the E=Enter key. Once the machine setter has checked the parameters they can be transferred to the machine’scontrol system by actuating softkeys ”IU Data transfer”, ”CU Data transfer” or ”Follow–uptakeover”. Input parameters can only be implemented on Password level 2. Note: Settings for the clamping unit Screen page ’99 ERGOSTART’ does not show either the calculated or the fixed settings for theclamping unit. The parameters can only be adjusted after data has been transferred to the relevant screen pages. The program determines: –
Mould and ejector stroke, calculated from component geometry
–
Speeds for the mould and ejector are set at 30% of maximum
–
Maximum clamping force of the machine
–
Ejector pressure is set at 100 bar (approx. 60% of the maximum ejector force)
Attention! The program does not allow for core puller movements or the air ejector. The parameters for these must be entered on the relevant screen pages.
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Screen page selection, input sequence and softkey functions – continued Note: Settings for the injection unit Injection pressure Injection pressure on the preliminary cycle is at a maximum to ensure that the set injection speedis achieved. Attention! When hot runner and multi–cavity moulds are used, injection pressure may need to be limited,even on the first cycle. Follow–up pressure Follow–up pressure is set to ”0” by actuating the ”IU Data transfer” softkey. Only when softkey ”Follow–up takeover” is actuated will the displayed value be transferred intothe machine control system. The follow–up pressure indicated is calculated from the maximum injection pressure measured inthe preceding cycle. Temperatures A recommendation is given for a temperature profile in the cylinder based on the material and on component specification. It follows that the melt temperature is taken as a maximum from the cylinder temperature profile. Ergostart also suggests a mould– and demoulding temperature, though these may need adjustment. Attention! Hot runner temperatures on hot runner moulds must be set to the melt temperature by themachine operator.
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Screen page selection, input sequence and softkey functions – continued Softkey functions Delete input
Select material
IU–Data transfer
Actuation of softkey ”Delete input” sets all parameters to ”0”.
Actuation of softkey ”Select material” opens a window on screen. The relevant material can beselected from this window.
Actuation of softkey ”IU–Data transfer” transfers all injection unit parameters, with the exceptionof follow–up pressure, into the machine control system. A message is displayed on screen – ”Settings have been transferred”. Please check prior to data transfer whether any of the settings need to be altered.
Follow–up takeover
Actuation of softkey ”Follow–up takeover” transfers the follow–up pressure, as indicated, intothe machine control system.
A message is displayed on screen – ”Setting has been transferred”.
CU–Data transfer
All parameters which have been calculated or set by the Ergostart program for mould andejector movement are transferred into the machine control system by actuation of softkey ”CU–Data transfer”. A message is displayed on screen – ”Settings have been transferred”. Attention! Following actuation of softkeys ”IU–Data transfer”, ”CU–Data transfer” and ”Follow–uptakeover” the relevant parameters in the machine control system are overwritten by the settingsdefined by Ergostart. This means that pre–set values might be lost and may need to be re– entered.
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4.5.7.7.2 Input data 4.5.7.7.2.1 Selecting the material
Select material
Actuation of softkey ”Select material” opens up a window on screen which offers a choice of 11types of material. Select the material type using Cursor up or Cursor down and confirm it with E=Enter. Thisaction also closes the selection window. Note: When the material type has been confirmed, the specific density of the material at roomtemperature is indicated. In the case of amorphous materials (ABS, PC, PMMA, PS, SAN) thiscan usually be confirmed if no other values are known. For partially crystalline materials (HDPE, LDPE, PA 6, PA 6.6, PP, POM) the density must beadjusted (see data sheets on material manufacturers or Campus data file).
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4.5.7.7.2.2 Entering the weight Shot weight (in g at room temperature) is entered for weight. Shot weight is composed as follows: Shot weight =
n x component weight + total sprue weight n = number of cavities in the mould
Note: The weight can be determined by: –
using scales
or –
from the volume of mould cavities Shot weight =
(n x component volume + total sprue volume) x density n = number of cavities in the mould Volume in cm3 Density in g/cm3 at room temperature
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4.5.7.7.2.3 Entering geometry data
H
Wall thickness
B
Diameter
H
Flow length
L End of flow path Gate Wall thickness
The largest dimensions of the moulded part are entered for geometry data. For circular components it is the diameter, or else the length L and width B which are entered (see diagram). Note: Flow length Flow length is defined as the longest distance between the gate and the end of the flow peth. The Ergostart program suggests a flow length which is calculated from the data entered oncomponent geometry. It may sometimes be necessary to correct this flow length. A rough estimate of flow length will suffice (accuracy 5%). Wall thickness As a rule, il is only the wall thickness on the moulded part itself which is relevant (wihout the sprue). If the wall thickness varles across the component, the wall thickness data must be entered, since this is a deciding factor in determining cooling time. The input variable must be exact.
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4.5.7.7.3 Ergostart flow diagram Start
Install mould
Select screen page ’99 ERGOSTART’ or press ”Service” and ”Ergostart” softkey
Select a material
Enter a different density
Density o.k. no yes Enter the weight
Enter the geometry data
Calculated settings and temperatures o.k.?
no
Enter different settings and temperatures
yes Enter hot runner temperatures
Press ”IU Data transfer”
1
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Ergostart flow diagram – continued 1
Mould movement already set?
Press ”CU Data transfer
no Mould and ejector movements in Set–up mode
yes
Distance property set?
Alter distances
no
yes Mould and ejector movements and locking in manual mode
Mould movements property set?
Alter settings
no yes Is maximum clamping force achieved?
Set maximum clamping force
no yes Set semi–automatic mode
Run a few cycles to optimise change–over point
press ”Follow–up takeover” Process optimisation
End
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4
Screen page ”101 PROZESS–INFORMATION” – Note on optimisation and setting of machine parameters
By pressing the softkey ”Process Inform.” in the softkey line on the screen page ’99 ERGOSTART’ chap. 4.5.7.7.1, the page ’101 PROZESS–INFORMATION’ is displayed.
”Process information” is tied to the ”Ergostart” program so the starting point is a rough basic machine setting with suitable temperatures (barrel, melt and mould), sufficient metering stroke, suitable back–pressure and a sensible injection speed. Information about each process step can be called up on screen page ’101 PROZESS–INFORMATION’. The setter is led systematically through process optimisation with the aid of ”Process information”. The aim of the system is to offer a standard procedure for process optimisation.
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Screen page ”101 PROZESS–INFORMATION” – Note on optimisation and setting of process parameters – continued Various process steps can be selected via a scrolling menu using the cursor keys or the shuttle wheel The following process steps are available:
General Optimising changeover point Activating holding pressure Optimising holding pressure Optimising holding pressure time Setting cooling time Setting screw speed Setting monitoring values
Note: To call up information insert the ”ERGOSUPPORT” floppy disk.
Press the Enter key to confirm the selected process step; the menu window closes and the corresponding info–window opens with appropriate information. To read the complete information, it can be scrolled using the cursor keys or shuttle. Note: The window is closed again by pressing the ”Back” softkey.
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4.5.7.9
4
Screen page ”102 EXPERTENSYSTEM” – Note on remedies for quality defects on the mouldings
By pressing the softkey ”Expert system” in the softkey line on the screen page ’99 ERGOSTART’ chap. 4.5.7.7.1, the page ’102 EXPERTENSYSTEM’ is displayed.
The starting point for the ”Expert system” is a partly optimised process, but still with a few quality defects on the part like surface defects or even processing problems. Information on various subjects can be called up via screen page ’102 EXPERTENSYSTEM’.
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Screen page ”102 EXPERTENSYSTEM” – Note on remedies for quality defects on the mouldings – continued Various subjects can be selected on a scrolling menu via the cursor keys or the shuttle wheel. The following subjects are included:
Surface defects – colour Surface defects – gloss Surface defects – flow–lines/clouds/streaks Surface defects – ripples Dimensions (size, distortion, weight) Mechanical properties Process conditions (demoulding, processing, etc.)
Note: To call up information insert the ”ERGOSUPPORT” floppy disk. Press the Enter key to accept the selected subjects; the selection window will close and an info–window with corresponding defects will open. The text in the softkey line will change.
Various defects can be selected on a scrolling menu using the cursor keys or shuttle wheel.
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Screen page ”102 EXPERTENSYSTEM” – Note on remedies for quality defects on the mouldings – continued Press the ”Fault descript.” softkey to accept the selected defect; the selection window will close and an info–window will open with the corresponding defect description will open. The text in the softkey line will change. For parameter related defects press the ”Correct. parameter” softkey to accept the selected defect; the selection window will close and an info–window with the appropriate remedies will open. The text in the softkey line will change. For design related defects press the ”Correct design” softkey to accept the selected defect; the selection window will close and an info–window with the appropriate remedies will open. The text in the softkey line will change. Note: The window is closed again by pressing the ”Back” softkey.
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4.5.8
Operation
Functions – Group Process – Description of the Screen Pages
PROCESS
4.5.8.1
Press Function Selection Key to select screen page ’52 CONT. PROCESS CONTROL’.
Screen page ”52 CONT. PROCESS CONTROL”
A measure of each is taken for each cycle and data from previous cycles is rolled down the column. The top line of data is the most recently collected, with a maximum of 16 previous cycles shown simultaneously. The last but one line shows the mean value of the 16 cycles, and the last line shows their range.
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Screen page ”52 CONT. PROCESS CONTROL” – continuation On machines with ”ZE 486 Ergosupport” an upper and lower warning limit can also be set. In addition when the warning limit monitoring is started, the process status of the machine is indicated by 3 coloured lights. The corresponding colours are: Red:
Machine has alarmed (see alarm list and error message bar)
Yellow:
the process has crossed a warning limit
Green:
the machine is producing within the warning limits
Example with Melt cushion Measure the cushion in automatic mode: Then set–up the upper and lower tolerances in relation to these measurements Set–up the allowed deviation in tenths of a percent (0,1 %) and select the corresponding programme option. Note: If the machine produces a reject percentage greater than this value within 1000 cycles then the machine continues only until the base position (as for Semi–Auto), and shows the appropriate alarm message The red alarm lamp also lights. Note: The machine continues to run when the pre–set number of permissible deviations amounts to 99. If the machine has a reject percentage less than the set limit for 1000 cycles, then the percentage counter is reset and starts again from zero Program switch ”Reset deviation” In manual and automatic modes it is possible to reset the registered UL/LL deviations with the ”Reset deviations” PG switch. Note: The total of all reject parts is recorded in the ”Rejects” counter, see screen page ’54 PRODUCTION COUNTERS’ chap. 4.5.8.3
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4.5.8.1.1 Screen Page ”52 CONT. PROCESS CONTROL” – changing of Softkey Line
By pressing the softkey ”Further..”, the softkey line is changed
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4.5.8.1.2 Screen page ”52 CONT. PROCESS CONTROL” – Warning Limits
By pressing the softkey ”Warning Limits” in the softkey line on the screen page ’52 CONT. PROCESS CONTROL’ chap. 4.5.8.1, the selection window with the screen pages ”Warning Limits” is opened and the softkey line changed over.
The warning limits, which warn the operator before the tolerance limits themselves have been reached, i.e. before rejects are produced, can be set in the opened window. The values for the warning limits can be set by manual inputs or by using the automatic warning limit calculation. Note: The ”Warning limit” window is closed again by pressing the ”Back” softkey.
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Screen page ”52 CONT. PROCESS CONTROL” – Warning Limits – continuation The first time a warning limit is exceeded, the error message ” Warning limit exceeded” is sent or, if Screen Page ’52 CONT. PROCESS CONTROL’ is open, an info–window opens with the error message ”ERROR warning limit exceeded”.
Press the Enter key to close the info–window. Note: In the ”Warning limit” window the last defect actual value and the number of deviations are displayed. At the same time the error message ”Warning limit violated” appears in the ”Warning limits” window. In addition the yellow warning lamp lights up.
Example:
Here the upper warning limit for the melt cushion has been violated. The last actual value was 4.02. The warning limit for the melt cushion has already been violated three times.
QUIT
Note:
QUIT
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All registered defect actual values are cancelled with the ”QUIT” softkey. At the same time the warning lamp changes from yellow to green.
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4.5.8.1.2.1 Automatic calculation of warning limits Note: Before automatic calculation of warning limits the system must be configured (see chap. 4.5.8.1.3). With the help of the set configuration, process parameters are calculated which are appropriate for this application. Activate parameters Press the ”activate parameter” softkey, to activate the process parameter program switches suggested by the system based on the configuration. At the same time an info–window opens in which it may be decided whether to accept the suggested parameters.
Press the enter key to accept the suggested parameters or the clear key to leave the program switches unchanged. The window then closes. Note: Additional process parameters can be accepted or the automatically suggested process parameters can be deactivated by manual operation of the appropriate program switches.
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Automatic calculation of warning limits – continuation Note: If the ”Parameters active” softkey is operated before the configuration is complete, an info–window opens.
Press the Enter key to close the window; at the same time the warning limits configuration window will open. Complete the missing parameters (see chap. 4.5.8.1.3). Start of automatic warning limit calculation Note: The limit value calculation should not be started until the process has stabilised, otherwise the startup phase will compromise the data collected To calculate the warning limits the maximum and minimum values for all process parameters are recorded over the next 50 cycles. Each maximum and minimum value during the 50 cycles of warning limit calculation is displayed in the UWL and LWL columns. Press the ”Calculate limits” softkey to start the calculation of warning limits; the softkey line will then change.
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Automatic calculation of warning limits – continuation
In addition the message ”Calculating limits” appears at the bottom of the warning limit window together with the number of cycles left until the end of the measurement.
Note: Cycle interruption If the machine is stopped during the 50 cycles of warning limit calculation, an info–window will open on the screen.
Press the Enter key to restart the warning limit calculation at once. (i.e. to rerun the 50 cycles) or the Clear key to continue the warning limit calculation where it left off. The window will then close. Cancelling the warning limit calculation Press the ”Stop” softkey to cancel the automatic warning limit calculation.
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Automatic calculation of warning limits – continuation Ending the automatic warning limit calculation After completion of the 50 cycles the system uses an algorithm to calculate the upper and lower warning limits, which are at a certain distance from the earlier maximum and minimum values. Meanwhile the machine runs on unchanged. At the same time and info–window opens in which it may be decided whether the calculated warning limits should be accepted and monitoring of the limits started, or whether the limits should be accepted without starting the monitoring.
Press the Enter key to accept the warning limits and start monitoring or the Clear key just to accept the calculated warning limits; the info–window will then close. Note: If monitoring is not started, the setter has the opportunity to check the calculated warning limits and if necessary to enter other values for the warning limits. In this last case, press the ”START” softkey to finally start monitoring.
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4.5.8.1.2.2 Starting and stopping the warning limit monitoring Starting the warning limit monitoring Press the ”START” softkey to start warning limit monitoring; the softkey line will then change.
In addition the message ”Monitor” appears at the bottom of the warning limit window.
Stopping the warning limit monitor Press the ”STOP” softkey to stop the warning limit monitoring.
4.5.8.1.2.3 Adopting warning limits as quality limits
Press the ”Accept CPC data” to adopt the calculated or entered warning limits as the quality limits. Process control is started at the same time.
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4.5.8.1.3 Screen page ”52 CONT. PROCESS CONTROL” – Warning limit configuration The window for ”Warning limit configuration” and for selection of ”Unavailable parameters” is called up by the ”Config.” Softkey on Page ’52 CONT. PROCESS CONTROL’ Kap. 4.5.8.1.2, and then the softkeys change.
The opened window is divided into 2 areas. 1st area: Program switches ”Unavailable parameters” By setting the corresponding program switch the setter can choose which process parameters are not available for monitoring. E.g. melt temperature or mould cavity pressure, because these parameters are not available in the current application even though they are present on the machine. If the setter is also not using the integral values, whose limits are set on Page ’24 MWE’, then these parameters too are marked as unavailable.
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Screen page ”52 CONT. PROCESS CONTROL” – Warning limit configuration – continuation 2nd area: Warning limit configuration The settings needed for the monitoring of appropriate process parameters are selected here. Amongst these are the moulded part data for: –
Material,
–
Wall thickness and
–
Flow length.
Note: These three parameters can also be taken from Ergostart (Screen page 99) by pressing the ”read Ergostart” softkey. The legend ” (larger) or < (smaller). Graphic display For a clearer overview the percentage allocation of the total energy consumption is displayed as a bar graph. Note: Once the process parameters have been changed, wait a few cycles for the process to stabilise before interpreting the energy metering figures.
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4.5.8.5
Operation
Screen page ”56 ANALYSIS OF CYC. TIME”
By pressing the softkey ”Cycl. time analysis” in the softkey line on the screen page ’52 CONT. PROCESS CONTROL’ chap. 4.5.8.1 the page ’56 ANALYSIS OF CYC. TIME’ is displayed.
duaration of actual cycle
start time within cycle
duaration of previous cycle
On this screen page the start time and duration of up to 15 selected parameters within the cycle can be displayed. The duration of each parameter in the current cycle is displayed both as a bar and as an absolute value. In addition the duration of each parameter in the previous cycle is displayed.
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ANALYSIS OF CYC. TIME – Programming, Deleating and Saving as well as Reading of Parameters Programming of parameters Proceed by means of cursor keys or by turning the shuttle wheel to the required input position in line of the respective parameter
Press the Enter key to open the selection window for the parameter display
Different parameter can be selected via the pop–up menu actuated by cursor keys or shuttle wheel. Press the Enter key to take over the selected parameter, at the same time the selection window is closed. The corresponding text for the selected parameter appears in the screen page at the input position.
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ANALYSIS OF CYC. TIME – Programming, Deleating and Saving as well as Reading of Parameters – continuation Deleting all programmed parameters in the display Press the ” OK &”, softkey if all parameters are to be erased and then re–entered. Saving of parameters Press the ” OK”, softkey in order to save the parameters after they have all been entered. Retrieving saved parameters If it is not wished to save new parameters after they have been entered, the ” OK –>”, softkey is pressed to display the previously saved parameters.
4.5.8.5.2
ANALYSIS OF CYC. TIME – Start / Stop and deletion of record Start recording Press the ”|→”, softkey to start the recording. Stop recording Press the ”"|”, softkey to stop the record. Deleting recording Press the ”0––>”, softkey to delete the recording.
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4.5.8.6 SPC – Statistical Process control 4.5.8.6.1 Screen page ”58 SPC – CONFIGURATION”
By pressing the softkey ”SPC” in the softkey line on the screen page ’52 CONT. PROCESS CONTROL’ chap. 4.5.8.1, the page ’58 SPC – CONFIGURATION’ is displayed.
The NC4 SPC system provides monitoring of the quality of production for the injection moulding machine. There are a maximum of 7 parameters that can be simultaneously monitored and configured. The SPC system fulfils two main functions Evaluating the process Monitoring the process
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Screen page ”58 SPC – CONFIGURATION” – continuation Subgroups of data are take at regular selectable intervals of time or cycles. The are statistically evaluated, and the results are plotted on control charts. The process can be documented using the automatic print–out option for the charts. Should the control charts cross the control limits, an alarm message is generated. Subgroups: by number of cycles, type in the interval as a number of shots (max. 255) by time, type in the interval in number of minutes (max. 255) Size of the subgroup (–210 Parts) After the set interval a set number of shots will be taken as a subgroup. If the subgroup size is greater than the interval (either in minutes or shots), the input value will be rejected. The fault message ”100% monitoring exceeded” will appear. It may be necessary to calculate the time interval so that this does not occur; multiply the number of shots per subgroup by the average cycle time and add one minute for minimum interval. Shot– or time– intervals can be modified during the SPC monitoring.
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Screen page ”58 SPC – CONFIGURATION” – continuation Status of the SPC: Before starting the SPC, it is important to type in the upper and lower limits for each process parameter for both mean variation (x) and sample deviation variation (s). In this way the control limits for both (x) and (s) are locked, and form the basis for a strict early warning quality monitoring system for parameter drift. Choose the parameter with the parameter scroll softkeys by the channel number and type in the tolerances and control limits. Calculation of control limits: If this programme option is not selected, the SPC system will monitor against the manually entered control limits for (x) and (s). If this option is selected, the SPC system will calculate the control limits from the last 20 subgroups. The programme option is on the page ’59 SPC CONTROL CHART’.
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Screen page ”58 SPC – CONFIGURATION” – continuation SPC Start: The evaluation begins with the start of the SPC system, this involves taking data for the selected process parameters over 50 cycles, and evaluating as follows: Centring of the process Check individual parameters for normality Group the data into subgroups The evaluation curve for each parameter can be seen on the page ’59 SPC CONTROL CHART’. The data will be checked during the evaluation for deviation across the tolerance band. During the first 50 cycles of the SPC the word ”Evaluation” will appear on the page ’58 SPC – CONFIGURATION’, which will then change to ”Monitoring” once the control limits for mean and sample deviation have been evaluated. SPC Reports: If the option for ”print after evaluation” is selected, then at the end of the evaluation period a control chart will be produced and printed. If the option for printing on alarm is selected, a control chart will be printed for the appropriate parameters whenever the tolerance band is crossed. When the PG – switch ”Print when control charts full” is set, after 31 Subgroups, the complete control charts for each selected parameter is printed. This means in effect that the whole of the SPC Study is documented.
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4.5.8.6.1.1 Screen page ”58 SPC – CONFIGURATION” Selection of monitored parameters
Parameter Parameter ––> 1.33 Pp and PpK: Process capability; a universal measure calculated during the monitoring phase and should be > 1.00 These standard measure of the process indicate its suitability for the 0product.
4.5.8.6.3 Printing of the SPC – Parameter
Print
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Selecting the softkey ”Print”, causes the following for the currently selected parameter to be printed: – during the calibration:
only the calibration values (x 50)
– during a study:
the / x / s control charts and important parameter characteristics.
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4.5.9
Operation
Function – Group Automation – Description of the Screen Pages Press Function Selection Key to select screen page ’600 AUTOMATION’.
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Screen page ”60 QC – PLOTTING” – Quality monitoring
By pressing the softkey ”QC–plotting” in the softkey line on the screen page ’600 AUTOMATION’ chap. 4.5.9, the page ’60 QC – PLOTTING’ is displayed.
This page allows the operator to select rejects and good parts (differentiated and monitored through the page ’52 CONT. PROCESS CONTROL’) chap. 4.5.8.1.2 as well collect test samples of the product. The mouldings can be separated to 3 or 2 separate positions depending on programming.
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Screen page ”60 QC – PLOTTING” – Quality monitoring – continuation The 3 position separation is in 3 directions as follows: OS = Operator Side NOS = Non–Operator Side Discharge tube The 3 types are: Good parts Test samples Rejects The 2 position separation is similar but without the discharge tube. The interconnected separators can be set–up using the softkeys in accordance with the operators requirements: to the discharge tube (only with 3 point separation) or to the operator side or to the non–operator side When the separation directions have been set–up, the display ”set–up by softkey” will disappear. By pressing the softkey base position, the separation directions will be set according to the allocation for the part. Example: (OS = Operator Side, NOS = Non–Operator Side) OS
NOS
3 – Pnt
2 – Pnt
Good
off
off
Discharge tube
OS
Q – test
on
off
OS
OS
Reject
off
on
NOS
NOS
The current set–up for separation is shown.
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Screen page ”60 QC – PLOTTING” – Quality monitoring – continuation Separation of test samples can be done in one of 3 ways: automatically after a selected number of cycles or automatically after a selected number of minutes or Manually using the Q – Key on the NC4 console No. in sample: Type in the number of consecutive mouldings required (max. 10) Start after cycle: After setting the programme option, the required parts are separated after the set number of cycles Repeat after cycle: After setting the programme option, the required parts are separated after the set number of cycles. Start after time: After setting the programme option, the required parts are separated after the set number of minutes. Repeat after time: When this programme option is selected, the required parts are repeatedly separated after the set number of minutes. In the intervening period, the remaining number of cycles or time to separation is displayed. Archiving Q–samples: By activating of the programme switch ( printer ), the statistic values of the Q – samples will be printed as report.
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4.5.9.2
Operation
Screen page ”46 PROGRAM INPUTS”
By pressing the softkey ”Program Inputs” in the softkey line on the screen page ’600 AUTOMATION’ chap. 4.5.9, the page ’46 PROGRAM INPUTS’ is displayed.
This displayed functions are released in each operating mode depending on up to 6 connectible external transmitters (e.g. limit switch) in each case or are interrupted again if the signal is lost. If the input signal is present at the corresponding input of the control system, the corresponding input number is displayed inversely on the screen. Note: A programmed input can be set several times.
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Programmable inputs – continuation In the heading of the respective column it is possible to type 2 lines (8 digits each) any text in. Typing the text Move the cursor to the input line Press the ”ABC” key on the console to activate all the ASCII character keys. During typing the keys for Manual operation are blocked.
”Shift”
”ABC”
Use the shift key for capitals.
End a line with the E=Enter key
Use the Clear key to delete. The rest of the line is then shuffled left. Example: ”Cores out” for all cores is dependent on a signal from input number 2. The programme option for channel 2 is switched–on for ”Cores out” and for the core selection is typed 0 = all and the input signal is connected to Input–number 2. Note: The connection for the input signals nr. 1–6 is via terminal rail – X100.1(.2), and is shown in the relevant electrical drawing. Note: Further informations see interface description chap. 5.4.14 ZE 450 – ZE 454 ”Freely Programmable Inputs/ Outputs” .
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Programmable inputs – continuation Following machine functions are available: Machine start Mould close Mould close from ..... to Note: If the PG switch ”Close mould from .... to” is switched on, the respective input signal must be within the specified stroke distance, otherwise the closing movement is interrupted and the machine waits for the missing input signal. Mould open Mould open from ..... to Note: If the PG switch ”Close mould from .... to” is switched on, the respective input signal must be within the specified stroke distance, otherwise the opening movement is interrupted and the machine waits for the missing input signal. Inj. unit forward Inj. unit retract Injection Holding pressure Dosing Core in with possibility of setting in the core No. (0 = ”all cores”) Core out with possibility of setting in the core No. (0 = ”all cores”) Ejector forward A / B Ejector return A / B Safety gate – Open (only on machines with autom. safety guard) Safety gate – Close (only on machines with autom. safety guard)
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Programmable inputs – continuation Missing input during machine function: A missing input does not interrupt the machine cycle, but the machine function waits for the missing input within the specified cycle monitoring time. If the missing input returns within the cycle monitoring time, the machine function continues to run. If the corresponding programmed input for the preselected function is missing, the fault message ”Programmable input missing” is put out in semi– or fully automatic operation after expiry of the cycle monitoring time. Acknowledgement of the fault message: With change–over to manual or setting and subsequent pressing of a manual function key the fault message is acknowledged. In these two operating modes the fault message is set, if the corresponding function is started by key and the programmed input for release is not present. On release of the key the fault message is acknowledged again. Opening of guard door during waiting machine function: If a guard door is opened and reclosed during a waiting machine function, the machine function (prerequisite – missing input now present) is continued again only when the start key is pressed.
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4.5.9.3
Operation
Screen page ”47 PROGRAM OUTPUTS” and ”48 PROGR. OUTP. 5,6”
By pressing the softkey ”Program outputs” in the softkey line on the screen page ’600 AUTOMATION’ chap. 4.5.9, the page ’47 PROGRAM OUTPUTS’ is displayed.
Note: By pressing the softkey ”progam ’48 PROGR. OUTP. 5,6 is displayed.
out.
5,6”,
the
page
Switch on– and Switch off events for up to 6 outputs can be programmed independently from one another. After the selected switch on event within the machine cycle is reached the output is activated until the assigned switch off event is reached. If the corresponding output is activated the corresponding input number is displayed inversely on the screen. In the heading of the respective column it is possible to type 2 lines (8 digits each) any text in.
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Screen page ”47 PROGRAM OUTPUTS” and ”48 PROGR. OUTP. 5,6” – continuation Typing the text Move the cursor to the input line Press the ”ABC” key on the console to activate all the ASCII character keys. During typing the keys for Manual operation are blocked.
”Shift”
”ABC”
Use the shift key for capitals.
End a line with the E=Enter key
Use the Clear key to delete. The rest of the line is then shuffled left. Example Output 2: On reaching trigger position 150,0 mm during mould opening output 2 is active. After the time–out over 0,8 s then the output 2 is switchet off. Example Output 1: At the start of injection output 1 is active. On reaching of end holding pressure output 1 is switchet off. Note: In both examples the outputs in ”Setting” mode are not active. In addition the outputs can be activated at any time (regardless of program sequence) by the softkeys on the Ergocontrol.
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Screen page ”47 PROGRAM OUTPUTS.” and ”48 PROGR. OUTP. 5,6” – continuation Attention! If the configurable inputs/outputs option is part of this contract, outputs should not be used to initiate/control hazards motion. If used to initiate/control hazards motion, Purchaser (or its third– party integrator, if applicable) is responsible for the proper guarding of the hazards motion and shall indemnify and hold seller harmless from and against any loss, expense, liability, claim or litigation regarding personal injury or property damage regarding the same. Purchaser should refer to the machine–operating manual or contact the seller’s service department regarding any question with respect to the proper use/operation of the outputs. Note: The connection of external peripherals is made via relais –K1 .... –K6 wired into terminal rail –1X100.1(.2), and is shown in the relevant electrical drawing. Note: Further informations see interface description chap. 5.4.14 ZE 450 – ZE 454 ”Freely Programmable Inputs/ Outputs” .
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4.5.9.3.1 Progr. outputs – Programming of Switch on–/Switch off events 1 Start
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position of the output Note: After selecting the input position, the softkey “Menu” appears in the softkey line.
Menu Press the Enter key or the ”Menu” softkey to call up the selection window for the ejector’s switch–on / switch–off events.
Different switch on–/off event can be selected via the pop–up menu actuated by cursor keys or shuttle wheel. Press the Enter key to take over the selected switch on–/off event; at the same time the selection window is closed. The corresponding text for the selected switch on–/off event appears in the screen page at the input position.
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Programmable outputs – Programming of Switch on–/Switch off events – continuation Following switch on–/off events are available: : 1 switch off event stroke dependent Delay time Run time
Run time
not active Run time (only for ”Switch off event” selectable) If ”Run time” was selected as switch off event, it is possible to set a running time in the ”Run time” line.
10.5 s Note: The output is activated after the switch on event is achieved and expiry of any set delay time and reset after expiry of the set running time. 1
switch off event stroke dependent
Mould close 100.5 mm
Start mould close Mould close stroke dependent
Note: If ”Mould close stroke dependent” was selected as switch on–/off event, the input parameter for the mould closing movement appears in the ”stroke dependent” line. After selection of the input position the switch on–/off event can be set as a function of the mould closing position. Mould locked Unlock mould 1 switch off event pos. dependent
Mould open
Mould open stroke dependent
180.5 mm Note: If ”Mould open stroke dependent” was selected as switch on–/off event, the input parameter for the mould opening movement appears in the ”Stroke dependent” line. After selection of the input position the switch on–/off event can be set as a function of the mould opening movement.
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Programmable outputs – Programming of Switch on–/Switch off events – continuation Mould open
Switch off event Stroke dependent
1 Injection stroke dependent 180.5 mm
Mould stopped Injection stroke dependent, with the possibility of setting IU–No..
Note: If ”Injection stroke dependent” is selected for the switch–on / switch–off events, the setting for the injection stroke will appear on the ”Stroke dependent” line. After selecting the input position the switch–on / switch–off events can be set according to the injection stroke. Start holding End of holding Retract injection unit Retract screw before dosing Injection unit stopped Retract screw after dosing Screw stopped 1
Start dosing
Switch off event
Dosing stroke dependent stroke dependent 180.5 mm
Dosing stroke dependent
Note: If ”Dosing stroke dependent” is selected for the switch–on / switch–off events, the setting for the dosing stroke will appear on the ”stroke dependent” line. After selecting the input position the switch–on / switch–off events can be set according to the dosing stroke.
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Programmable outputs – Programming of Switch on–/Switch off events – continuation Dosing stopped End of cooling time
1 Switch on event
Part counter
stroke dependent Delay time Enter set counter Actual
10,0 s 150 112
Part counter (valid for switch on event) with the possibility of setting set counter; in addition, the actual counter can be reset manually.
Note: If ”Part counter” was specified as switch on event, the input parameter for set counter as well as the switch for maunal reset of actual counter appears under the switch on event. After selection of the input position the switch on event can be set as a function of good parts. Note: Each good part will decrement the actual counter. If the actual counter achieves the value ”0”, the output is connected and the actual counter is again set automatically to required value.
1
Start core in with possibility of setting in the core No. (0 = ”all cores”)
Start core in Core 2
Note: If ”Start core in” was selected as switch on–/off event, the line ”Core _” appears under the switch on–/off event. up After selection of the input position the switch on–/off event can be assigned to a specific core (by actuation of the larger/ smaller key). down
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Programmable outputs – Programming of Switch on–/Switch off events – continuation Core is in with possibility of setting in the core No. (0 = ”all cores”) Input of the assignment: see ”Start core in” note Start core out with the possibility of setting in the core No. (0 = all cores). Input of the assignment: see ”Start core in” note Core is out with the possibility of setting in the core No. (0 = ”all cores”). 1
Input of the assignment: see ”Start core in” note
Ejector forward
Ej. forward position dependent with the possibility of specifying the ejector stroke.
Stroke
A
55,9 mm
up
Note: If ”Ej. forward position–dependent” was selected as switch on–/off event, the line ”Stroke ....” and the input parameter for the ejector stroke appear under the switch on–/off event.
down
After selection of the input position the switch on–/off event can be assigned to a specific ejector stroke or both (by actuation of the larger/smaller key) and the start set as a function of the ejector position.
1 Ej.forward Stroke
Ejector is forward with the possibility of specification of the ejector stroke.
A Note: If ”Ejector is forward” was specified as switch on–/off event, the line ”Stroke ....” appears under the switch on–/off event. After selection of the input position the switch on–/off event can be assigned to a specific ejector stroke or both (by actuation of the larger/smaller key)
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Programmable outputs – Programming of Switch on–/Switch off events – continuation 1 Ejector back Stroke
- Ej. back stroke dependent with the possibility of specification of the ejector stroke. B
102,8 mm Note: If ”Ej. back stroke dependent” was selected as switch on–/off event, the line ”Stroke ....” and the input parameter for the ejector stroke appear under the switch on–/off event. Inputs: see note ”Ej. forward stroke dependent”. 1 Ej. is back
Ejector is back with the possibility of specification of the ejector stroke.
Stroke A,B Note: If ”Ejector is back” was selected as switch on–/off event, the line ”Stroke _” appears under the switch on–/off event. Inputs: see note ”Ejector is forward”. Ejector stopped Cycle start Cycle end Rejects Good parts Safety gate is closed Safety gate is not closed Selected mode
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4.5.9.3.2 Programmable outputs – Setting parameter delay times Activation delay If the switch on event was achieved, the output is activated only after expiry of the set delay time. esetting delay If the switch off event was achieved, the output is reset only after expiry of the set delay time.
4.5.9.3.3 Programmable outputs – Program preselector Switch Output ”aktiv” By switching on the respective PG switch it can be selected in which operating mode the output is activated. Following operating modes are selectable: SETTING HAND SEMI–AUTOMATIC AUTOMATIC Note: The output can also be programmed in such a way that the output is activated in several operating modes (e.g. by switching on SETTING and AUTOMATIC).
4.5.9.3.4 Programmable outputs – Program preselector Switch ”Softkey aktiv” If the PG switch is switched on, the output can be activated at any time (independently of the progr. sequence) and in all operating modes via the softkeys ”output 1” ... ”output 6” on/off the Ergocontrol. operate output
By pressing the softkey ”operate output” in the softkey line on the screen page ’47 PROGRAM OUTPUTS’ or ’48 PROGR. OUTP. 5,6’, the softkey line can be changed.
on/off
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on/off
on/off
on/off
on/off
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4.5.9.4 CAP Job 4.5.9.4.1 Screen page ”65 CAP – ORDER”, Job – Computer aided Production
By pressing the softkey ”CAP” in the softkey line on the screen page ’600 AUTOMATION’ chap. 4.5.9, the page ’65 CAP – ORDER’ is displayed.
The NC4 collects production data and compiles shift and job reports. Before a job is started it is essential that all the identifying data that go with the job are typed–in. The target production count and number of cavities are type into the page ’45 MOULD CATALOGUE’ chap. 4.5.8.3.
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Screen page ”65 CAP – ORDER”, Job – Computer aided Production – continuation When the job starts, press the ”Job Start” softkey so that the system can register the time and date of the start. During the course of the job the outstanding time required will be continually calculated and displayed. If the target volume of number of cavities is altered, the outstanding time will be adjusted accordingly. The start–up count will be determined by the start–up programme on the page ’42 STARTUP PROGRAM’ chap. 4.5.7.3. Note: The softkey for ”Job Start” is only functional after the softkey ”Job End” has been pressed.
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4.5.9.4.2 Screen page ”67 CAP – SHIFT” – Computer aided Production
By pressing the softkey ”CAP Shift” in the softkey line on the screen page ’65 CAP – ORDER’ chap. 4.5.9.4.1, the page ’67 CAP – SHIFT’ is displayed.
Identification of the shift supervisor at the start of a shift At the beginning of a shift, the shift supervisor must type in his personnel number.
Display of the length of a stoppage The length of a stoppage is shown in minutes, and to left of it is shown the frequency of stops.
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Screen page ”67 CAP – SHIFT” – Computer aided Production – continuation Allocation of a stoppage cause The allocation of a stoppage cause is effected by the programme option when done manually, or it may be effected automatically.. Note: Before a stoppage is allocated to a stoppage cause, the display shows the stoppage as undefined, and a time value is set against this text. Whenever a cause is then subsequently allocated to the stoppage, the time that has so far run as undefined, is automatically added to the current stop time. If however, the machine is re–started without allocation of the stoppage cause, then the undefined time value is accumulated to the undefined stoppage total. Utilization on % The % utilization is calculated per shift as follows: Utilization = shift time – stoppage total / shift time and shown graphically. Printing of the shift data at the end of a shift
Shift End
Pressing the ”Shift End” softkey produces a printed report of the shift data and calculations. The displayed data is then immediately reset where appropriate.
Startup Program
Note: A central computer collects the data automatically at shift end.
Identification of the shift supervisor at change of a shift For the subsequent shift the shift supervisor must type in his personnel number.
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4.5.9.4.3 Screen page ”68 CAP – REJECTS” – Computer aided Production
By pressing the softkey ”CAP–rejects” in the softkey line on the screen page ’65 CAP – ORDER’ chap. 4.5.9.4.1 or ’67 CAP – SHIFT’ chap. 4.5.9.4.2, the page ’68 CAP – REJECTS’ Sis displayed.
The data on this page relates to the current shift, and is reset to zero at the end of shift. Display parameter ”Total reworkable” The total for re–workable rejects is made up of the values input for re–workable rejects on the page ’67 CAP – SHIFT’ chap. 4.5.9.4.2. Display parameter ”Assign manual Rejects” This is the sum of manually entered scrap from page ”67 CAP – SHIFT” chap. 4.5.9.4.2, that has not been assigned to one of the possible causes.
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4.5.9.4.4 Screen page ”69 CAP – STATISTIC” – Computer aided Production
By pressing the softkey ”CAP statistic” in the softkey line on the screen page ’65 CAP – ORDER’ chap. 4.5.9.4.1 or ’67 CAP – SHIFT’ chap. 4.5.9.4.2, the page ’69 CAP – STATISTIC’ is displayed. By pressing the softkey ”CAP Statistic” in the softkey line on the screen page ’68 CAP – REJECTS’ chap. 4.5.9.4.3, the page ’69 CAP – STATISTIC’ is displayed.
The data on this page relates to the current shift, and is reset to zero at the end of shift. Graphical display of the reject The various reject types (0–15) on the page ’68 CAP – REJECTS’ chap. 4.5.9.4.3 are shown graphically ”Total manual rejects” are divided into (0–15) classes and shown as a bar graph ”The total process rejects” are also shown on the same bar graph.
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4.5.10
Operation
Function – Group Handling – Description of the Screen Pages Press Function Selection Key to select screen page ’78 ROBOT – EUROMAP 67’.
4.5.10.1
Screen page ”78 ROBOT – EUROMAP 67”
LH side of page Injection moulding machine operation display
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RH side of page Handling operation display
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Screen page ”78 ROBOT – EUROMAP 67” – continuation Operating status display The operating status is set on the handling unit by the injection moulding machine (IMM) IMM is not in semi–automatic or automatic cycle
IMM is in semi–automatic or automatic cycle, Start signal for handling IMM – Handling unit connection
IMM working without handling operation
IMM working with handling operation
4.5.10.1.1Screen page ”78 ROBOT – EUROMAP 67” – IMM Operation Display
Safety gate status display
Safety gate open
Safety gate closed The symbol is displayed highlighted while the function is present. If the safety gate is closed the status is indicated by a status tick. The “Safety gate closed” symbol remains highlighted in the closed condition as long as the function remains active.
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Screen page ”78 ROBOT – EUROMAP 67” – IMM Operation Display – continuation Mould status display
Mould open
Mould close Mould open The left status tick is set when the “Mould Open” position is reached. The right status tick is set when the intermediate position is reached. Note: If your handling unit is still equipped with the EUROMAP 12 standard electrical interface, the input of an intermediate position is not possible. Mould close The status tick is set when the “Mould locked” position is reached. The corresponding symbol remains highlighted as long as the function is present, i.e. until the corresponding status tick is set. Between the symbols the current actual stroke value of the mould is displayed. Ejector status display
Ejector stroke A / B back Ejector stroke A / B forward The appropriate status tick is set when the corresponding ejector position is reached. The corresponding symbol remains highlighted as long as the function is present, i.e. until the corresponding status tick is set. Between the symbols the current actual stroke value of the ejector is displayed. Note: If the Program Switch “Without handling consent” on Screen Page ’11 EJECTOR’ is selected for Ejector Stroke A or B, or if the ejector stroke is not programmed on Screen Page ’16 MOULD ... SEQUENCE’, then this stroke is blanked out on the page.
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Screen page ”78 ROBOT – EUROMAP 67” – IMM Operation Display – continuation Core status display
Core is OUT
core number
Core is IN
The appropriate status tick is set when the corresponding core has reached its position. The corresponding symbol remains highlighted as long as the function is present, i.e. until the corresponding status tick is set.
Note: If the Program Switch “Without handling consent” on Screen Page ’14 CORES’ is selected for a core, or if the core is not programmed on Screen Page ’16 MOULD ... SEQUENCE’, then this stroke is blanked out on the page The cores can be split into two different core and status groups.
Status / core group
Core / status group Note: If your handling unit is still equipped with the EUROMAP 12 standard electrical interface, only one core group can be selected.
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Screen page ”78 ROBOT – EUROMAP 67” – IMM Operation Display – continuation Core group Assignment of a given core function to one of the two core groups. The in and out movements of a core number can only be assigned to the same core group, thus the entry is only possible with core out movement. Status group Assignment of a given individual status to one of the two status groups. The in and out movements of a core number can only be assigned to the same status group, thus the entry is only possible with core out movement.
4.5.10.1.2Screen page ”78 ROBOT – EUROMAP 67” – Handling mode display
Handling safety switch
The status tick is set when the mechanically adjusted (mould space) safety switch is free. Without the status tick the mould receives no consent from the handling. Reject
If the status tick is set a reject part is signalled to the handling unit by the IMM. This function is used for a separate reject deposit position.
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Screen page ”78 ROBOT – EUROMAP 67” – Handling mode display – continuation Mould consent
Mould open
Mould close Mould open The left status tick is set when the “Mould open” position is reached and signalled to the handling unit by the IMM. The right status tick is set when the intermediate position is reached and signalled to the handling unit by the IMM. Note: If your handling unit is still equipped with the EUROMAP 12 standard electrical interface, the input of an intermediate position is not possible. Stroke display The set value given on Screen Page ’17 SEQUENCE PARAMETER’ for the intermediate position is shown here between the symbols. Mould close The status tick is set when the “Mould locked” position is reached and signalled to the handling unit by the IMM. Red cross in front of mould close No consent from the handling for mould close. Green arrow in front of mould close Consent from the handling for mould close.
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Screen page ”78 ROBOT – EUROMAP 67” – Handling mode display – continuation Mould opening and handling at intermediate mould stop Note: If your handling unit is still equipped with the EUROMAP 12 standard electrical interface, the input of an intermediate position is not possible. Entry of intermediate position
If the handling unit is to be used with an intermediate mould stop, it must be programmed on Screen Page ’16 MOULD ... SEQUENCE’.
Move parallel with Set position Check position
The values of the set and control positions for the intermediate stop are set on Screen Page ’17 SEQUENCE PARAMETER’. The handling unit will move at the intermediate stop or simultaneously. Note: Entry of the positions for handling intermediate stop in Screen Page ’17 SEQUENCE PARAMETER’ is only possible if Handling with Intermediate Stop has also been programmed on Screen Page ’16 MOULD ... SEQUENCE’. Note: Intermediate stop position reached status is always sent from the IMM to the handling even if no intermediate stop position has been programmed. Red cross in front of mould open (with mould intermediate stop) No consent from handling for mould opening from intermediate stop to mould open position. Green arrow in front of mould open (with intermediate stop) Consent from handling for mould opening from mould intermediate stop to mould open position. If the handling moves from the intermediate stop position into the mould space, the “Mould–space free” signal is lost. Further mould movements are not possible until the handling sends a “Mould open” consent signal.
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Screen page ”78 ROBOT – EUROMAP 67” – Handling mode display – continuation Ejector consent
Ejector Return
Ejector Advance When ejector strokes A and B have reached their positions in the relevant directions (corresponding ticks must be present), this combined status is signalled to the handling by the IMM If only one stroke is monitored then the single status is signalled. Red cross in front of a symbol Strokes A and B have no consent from the handling to move in that direction. Green arrow in front of a symbol Strokes A and B have consent from the handling to move in that direction. If only one stroke is monitored, the consent is only for that stroke. Core consent
Move core OUT Core groups Move core IN 1 and 2 Combined status When all single status signals for an assigned status group are present for a given core function, this combined status is signalled to the handling by the IMM and the status tick for the group is set. Red cross over the symbol No cores assigned to this group, have consent from the handling for the corresponding function. Symbol without red cross All cores assigned to this group, have consent from the handling for the corresponding function.
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Screen page ”78 ROBOT – EUROMAP 67” – Handling mode display – continuation Note: If your handling unit is still equipped with the EUROMAP 12 standard electrical interface, only one core group can be selected. Combined status If each single status for cores is set OUT or IN then this combined status is signalled to the handling by the IMM. Red cross over symbol No cores have consent from the handling for this function. Symbol without red cross All cores have consent from the handling for this function.
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4.5.11
Function – Group Information – Description of the Screen Pages Press Function Selection Key to select screen page ’80 PAGE LAYOUT’.
i 4.5.11.1
4
Screen page ”80 PAGE LAYOUT”
This page shows the layout of all the installed pages on the NC4 system, with a text description and number for quick access. A page can be selected: either by moving the cursor or by turning the shuttle wheel to highlight the text description and pressing E=Enter; or by typing the quick access number that appears next to the page.
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4.5.11.2 SETUP – Screen pages 4.5.11.2.1 Screen page ”83 SETUP” – Setting of general functions
By pressing the softkey ”Setup” in the softkey line on the screen page ’80 PAGE LAYOUT’ chap. 4.5.11.1, the page ’83 SETUP’ is displayed.
The operator has a choice of set–up configurations. Note: Complete ”Printer setting” and ”Date and time setting”, the programme option ”Amendment report” and entry of ”Reasons for amendment” are only possible from password level 3 and above. Programme option ”Password Chip–card” is only possible with password level 5.
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4.5.11.2.1.1 Screen page ”83 SETUP” – Setting of ”Button click” Button click ON / OFF Button click 30 Screen saver shutdown Alarm page automatic
Proceed by means of cursor keys or by turning the shuttle wheel to the switch ”Button click”.
Press the Enter–key to confirm the Button click ON / OFF. If the switch ”Button click ON / OFF” is set, an acoustic signal sounds when pressing any key.
4.5.11.2.1.2 Screen page ”83 SETUP” – Setting of ”Screen saver shutdown” Screen–Saver in minutes after last use (up to max. 99 minutes)
Button click 30 Screen saver shutdown Alarm page automatic
Proceed by means of cursor keys or by turning the shuttle wheel to the input position in the line ”Screen saver shutdown” Set the new required value. Alarm page appears automatically when more than one alarm occurs ON / OFF Note:
MAX: 99 MIN: 0
OLD: 30
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen.
Press the Enter key to take over the new required value; at the same time the info window is closed.
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4.5.11.2.1.3 Screen page ”83 SETUP” – Setting of ”Alarm page automatic” Button click 30 Screen saver shutdown Alarm page automatic
Alarm page appears automatically when more than one alarm occurs ON / OFF Proceed by means of cursor keys or by turning the shuttle wheel to the switch ”Alarm page automatic”. Press the Enter–key to switching the Alarm page ON / OFF. If the switch ”Alarm page automatic” is set, the alarm page appears automatically when more than one alarm occurs.
4.5.11.2.1.4 Screen page ”83 SETUP” – Setting of ”Amendment report log” and set–up of change reasons Button click 30 Screen saver shutdown Alarm page automatic Amendment report log
Amendment report log ON / OFF Proceed by means of cursor keys or by turning the shuttle wheel to the switch ”Amendment report log”.
Password chip–card
Press the Enter–key to switching the Amendment report log ON / OFF. If the switch ”Amendment report log” is set, the ”Amendment report” is kept automatically when changes are made. Change reason 1 Einfallstellen Gradbildung Gradbildung 5
Change reason For the amendment report for settings, up to 15 different reasons can be set–up in text (15 characters). Proceed by means of cursor keys or by turning the shuttle wheel to the input position of change reason.
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Screen page ”83 SETUP” – Setting of ”Amendment report log” and set–up of change reasons – continuation
Set–up of change reasons The ”change reasons” can be entered via the Ergocontrol keyboard. The ”ABC...” key switches the Manual and ”F” keys into ASCII characters. The ”Shift” key selects capital letters.
”Shift”
”ABC”
The text is accepted by pressing of Enter key.
4.5.11.2.1.5 Screen page ”83 SETUPP” – Setting of Release of Screen Page for Operation via Password Input / Chip–Card Button click 30 Screen saver shutdown Alarm page automatic Amendment report log
Proceed by means of cursor keys or by turning the shuttle wheel to the switch ”Password chip–card”.
Password chip–card
Press Enter key to switch over release of Screen Page for Operation via Password Input or Chip–Card.
If the switch ”Password chip–card” is switched on, the release of Screen Page for Operation takes place via chip–card inserted in Ergocontrol.
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4.5.11.2.1.6 Screen page ”83 SETUP” – Setting of measurements Measurements mm Stroke [ccm/s] v–Inject. Temperatures C [mm/s] Rotation [ccm] Vol/SC–Str. bar Press. p_spec Press.
Conversion of measurements Stroke: v–Injection: Temperatures: Rotation: Vol./SC–Str.: Pressure: Pressure:
mm – inch ccm/s – cu.in./s, mm/s – in./s C – F U/min – RPM, mm/s – in./s ccm – cu.in., mm – in. bar – psi pspez – phydr
Proceed by means of cursor keys or by turning the shuttle wheel to the switch of respective unit of measurement. Press the Enter key to switch over the unit of measurement.
4.5.11.2.1.7 Screen page ”83 SETUP” – Setting of time and date Button click 30 Screen saver shutdown Alarm page automatic Amendment report log Password chip–card Mi 22.03.00
13:22:40
Setting of actuelle time and date Proceed by means of cursor keys or by turning the shuttle wheel to the required input position. Typ the desired value for date and time. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first.
Press the Enter–key to confirm the typed value.
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4.5.11.2.1.8 Screen page ”83 SETUP” – Setting of printers and the page length Printer Type HP–Laser Channel Parallel1 Page length 10 Line COM1 COM2 Baudrate 19200 19200 Stopbits/ 1/NO 1/NO Parity
Report
Page length Number of lines per printed sheet, max. 99, for page print–outs Proceed by means of cursor keys or by turning the shuttle wheel to the input position in the line Page length. Set the new required value. Shall the set value be modified directly by using the shuttle wheel, press the Enter key first. Note:
MAX: 99 MIN: 10
OLD: 10
If the required value is changed, an info window with the possible limit values and the old required value appears in the top right– hand corner of the screen.
Press the Enter key to take over the new value; at the same time the info window is closed. external printer parallel Note: Using a external printer parallel the cannel ”Parallel 1” have to be selected.
Printer Type HP–Laser Intern Channel Parallel1 Epson FX 10 Page lengthe HP–Laser COM1 COM2 PCL–5(Color) Baudrate 19200 19200 Sonder Stopbits/ 1/NO 1/NO Graphic(Disk) Parity Report
Note: If the channel ”File” is selected the printing–file is storted on diskette (in the format of the selected printer). For this a diskette has to be inserted in the internal diskette drive. Selection of the printer Proceed by means of cursor keys or by turning the shuttle wheel to the input position of the printer type.
Press the Enter key to open the selection window for the printer type.
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Screen page ”83 SETUP” – Setting of printers and the page length – continuation The following printer types can be selected via the pop–up menu actuated via cursor keys or shuttle wheel. EPSON FX HP–Laser PCL–5 (Color) Special Graphic(Disc) Note: With printer type ”Graphic(Disk)” the screen pages can be saved to floppy disk in GIF format. Note: The printer type ”sonder” is provided for future applications. Press the Enter key to take over the printer selected; at the same time the info window is closed.
Printer Type HP–Laser Channel Parallel1 Parallel 1 Page length Parallel 2 COM1 COM 1 Baudrate 19200 19200 COM 2 Stopbits/ 1/NO 1/NO File Parity
Report
The corresponding printern appears in the screen page at the input position. Selection of channel
Proceed by means of cursor keys or by turning the shuttle wheel to the input position of the channel.
Press the Enter key to open the selection window for the channel. Select channel ”Parallel 1” via the pop–up menu actuated via cursor keys or shuttle wheel. Press the Enter key to take over the channel selected; at the same time the info window is closed. The corresponding channel ”Parallel 1” appears in the screen page at the input position.
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Screen page ”83 SETUP” – Setting of printers and the page length – continuation external printer serial If a Printer has a COM1 or COM2 serial interface, the printer type, Bautrate, Stopbits/parity and transmission protocol has to be set according to the parameters of the printer set. Note: Using a external printer serial the cannel ”COM 1” or ”COM 2” has to be selected. Selection of printer and channel, see external printer parallel. Printer Type HP–Laser Channel COM1 Page length 10 Zeilen COM1 COM2 Baudrate 19200 19200 Stoppbits/ 1/NO 19200 1/NO Parity 9600
Report 4800
The serial interfaces for COM1 and COM2 can be freely configured. Selection of Baudrate
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position in column COM1 or COM2.
2400 1200
Press the Enter key to open the selection window for the Baudrate. The following Baudrates can be selected via the pop–up menu actuated via cursor keys or shuttle wheel. 19200, 9600, 4800, 2400, 1200 Press the Enter key to take over the Baudrate selected; at the same time the info window is closed. The corresponding Baudrate appears in the screen page at the input position.
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Screen page ”83 SETUP” – Setting of printers and the page length – continuation Page length
10 Line
COM2 COM1 Baudrate 19200 19200 1/NO Stoppbits/ 1/NO Parity 1/NO
1/ODD Report 1/EVEN 2/NO 2/ODD 2/EVEN
Selection of Stopbits/Parity
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position for the Stopbits/Parity in column COM1 or COM2.
Press the Enter key to open the selection window for the Stopbits/ Parity. The following Stoppbits/Parity can be selected via the pop–up menu actuated via cursor keys or shuttle wheel. 1/NO, 1/ODD, 1/EVEN, 2/NO, 2/ODD, 2/EVEN Press the Enter key to take over the Stoppbits/Parity selected; at the same time the info window is closed. The corresponding Stoppbits/Parity appears in the screen page at the input position. Page length
10 Line
COM2 COM1 Baudrate 19200 19200 1/NO Stoppbits/ 1/NO Parity
Report No XON/XOFF RDY/BUY
Selection of transmission report
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position for the Report in column COM1 or COM2.
Press the Enter key to open the selection window for the report type.
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Screen page ”83 SETUP” – Setting of printers and the page length – continuation The following Reports can be selected via the pop–up menu actuated via cursor keys or shuttle wheel. no, XON/XOFF or RDY/BUY Press the Enter key to take over the report type selected; at the same time the info window is closed. The corresponding report type appears in the screen page at the input position. integrated printer Using the integrated printer (ZE 790) the cannel ”Parallel 2” has to be selected. Selection of printer and channel, see external printer parallel.
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4.5.11.2.2 Screen page ”183 SETUP MACHINE” – PG–Switch for Release of programming of mould sequnce, axis monitoring and Screw–back stop Maximum
By pressing the softkey ”further...” in the softkey line on the screen page ’10 MOULD SETUP’, the softkey line is changed.
By pressing the softkey ”Setup machine” on the screen page ’10 MOULD SETUP’ chap. 4.5.4.1, the page ’183 SETUP MACHINE’ is displayed.
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Screen page ”183 SETUP MACHINE” – PG–Switch for Release of programming of mould sequnce, axis monitoring and Screw–back stop Maximum – continuation Note: This programme options for “Programming of mould sequnce” and “Screw–back stop Maximum” can only be operated from password level 4 and above. The PG switches can be changed only in the ”Manual” operating mode with the machine Stationary. PG–Switch for enabling sequence programming By switching on the respective PG switch, it can be selected which programming of the movement sequence for cores ejector and Injection Units is approved. The following sequence programming can be selected: basic sequence flexible sequence without repetition flexible sequence with repetitions flexible sequence IU Note: Programming of the movement sequence The movement sequence is programmed in screen page ’16 MOULD ... SEQUENCE’ (see chap. 4.5.4.3.1). PG–Switch “Manual: Dosing stop maximum” If the PG–switch “Manual: Dosing stop maximum” is selected then in manual mode normal operation of the dosing (metering) key allows screw–back past the dosing stop position as far as the maximum possible stroke. PG–Switch “Axis monitoring switched off’” If the PG–switch “Axis monitoring switched off” is selected, then there is no monitoring of the mould movement For function of Axis monitoring, see Chap. 4.5.4.1.2.
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4.5.11.3 General text data – Indication and Typing of Text Informations 4.5.11.3.1 Screen page ”81 GENERAL DATA TEXT 1”
By pressing the softkey ”General Data 1” in the softkey line on the screen page ’80 PAGE LAYOUT’ chap. 4.5.11.1, the page ’81 GENERAL DATA TEXT 1’ is displayed.
Screen page ’81 GENERAL DATA TEXT 1’ Screen page ’82 GENERAL DATA TEXT 2’ Both these pages can hold information down–loaded from a central computer. It is also possible to type data in from the NC4 console keypad.
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Screen page ”81 GENERAL DATA TEXT 1” – continuation Typing text: Move the cursor to the input line Press the ”ABC” key on the console to activate all the ASCII character keys. During typing the keys for Manual operation are blocked.
”Shift”
”ABC”
Use the shift key for capitals.
End a line with the E=Enter key
Use the Clear key to delete. The rest of the line is then shuffled left.
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4.5.11.3.2 Screen page ”82 GENERAL DATA TEXT 2”
By pressing the softkey ”General Data 2” in the softkey line on the screen page ’81 GENERAL DATA TEXT 1’ chap. 4.5.11.3.1, the page ’82 GENERAL DATA TEXT 2’ is displayed.
Operating:
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4.5.11.4
4
Screen page ”84 PRINTING” – Printing from Screen pages, Reports and Records
By pressing the softkey ”Print” in the softkey line on the screen page ’80 PAGE LAYOUT’ chap. 4.5.11.1, the page ’84 PRINTING’ is displayed.
The following information can be printed from the Ergocontrol, either using the internal printer (parallel) or using either an external serial printer (COM1 set–up on the page ’83 SETUP’) chap. 4.5.11.2 or an external parallel printer. The printouts will come with a ”header text” e.g Machine No. or Part Description. Note: The printing process can be started manually via softkeys or manual function key or automatically with corresponding programming.
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Screen page ”84 PRINTING” – continuation Enter of header text
The ”header text” can be entered via the Ergocontrol keyboard. Pressing the Ergocontrol–key ”ABC...” switches the Ergocontrol keyboard to the ASCII character mode.
”Shift”
The Ergocontrol ”shift” key changes from ordinary letters to capital letters.
”ABC”
Press the E=Enter key to accept the header.
4.5.11.4.1 Manual Start and interuption of a printing via Softkeys All pages: Print Everyth.
Reset Print
The ”Print Everyth.” softkey starts printing all the available pages immediately it is pressed. Amendment report,alarms and mould catalogue:
Print Lists
Printer Function
Mould Amendment Catalogue Report
Amended List
Alarm liste
Alarm List
Mould Änderungs Catalogue liste
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Press the softkey ”Print Lists”, then the softkey line is changed.
Selecting the softkey for ”Amendment Report” produces a print–out of the amendment report.
Selecting the softkey for the ”Alarm List” produces a print–out of the alarm texts in the buffer.
Alarm List
Selecting the softkey for mould catalogue produces a print– out of the contents of the mould catalogue diskette.
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Manual Start and interuption of a printing via Softkeys – continuation Note: Print Everyth.
Reset Print
Interuption of a printing On the main print selection page, the ”Reset Print” softkey interrupts any printing that is taking place.
Line–, Sheet Advance To execute a line–feed, or form–feed on the printer, first select the softkey for printer functions, then the corresponding key for the function.
Print Lists
Printer Function
Press the softkey ”Printer Function” to change the softkey line.
Line Sheet Advance Advance
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4.5.11.4.2 Manual Start of a printing via Manual Function Key ”Hardcopy”
Hardware button ”Printer Hardcopy” Any page that appears on the Ergocontrol console can be printed– out simply by pressing the ”Printer Hardcopy” key nest to the machine control keys, while the page is being displayed.
4.5.11.4.3 Automatic Start of a printing according to selected program options Protocols Alarm change: When programme option for alarm changes it selected, all changes in alarm statu, including new alarm occurrences, are printed–out as they occur, together with time and date. Operation mode change: When the softkey for mode change is selected, any changes in operation mode, such as Manual to Automatic etc. are printed–out, together with time and date. C A P: If a central computer is not being used to assess production performance, the shift data on the page ’67 CAP – SHIFT’ can be printed by pressing the softkey for shift end. However, note that CAP data values will be reset in this case. By pressing the job end softkey, both the pages ’65 CAP – ORDER’ and ’67 CAP – SHIFT’ will be printed and reset.
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Automatic Start of a printing according to selected program options – continuation Reports: Select the softkey for ”automatic reports” Choose between ”reports by cycle” count, or ”reports by time”, and enter the cycle interval or time interval in minutes. In the field for subgroup size, type in the number of lines of statistics desired up to a maximum of 99. Manual Report
Reset Report
The ”Reset Report” softkey, resets the interval timer to zero, so that a full interval is required before the next print–out. The pages and process statistics softkeys cause the respective pages and subgroup size in the page ’50 PROCESS – STATISTIC 1’ for the selected parameters to be printed. Note:
Manual Report
By pressing the ”Manual Report” softkey produces a print– out of the data for the last cycles on the ’50 PROCESS – STATISTIC 1’ together with the selected pages.
Reset Report
Any alarms or changes in operation mode will be automatically included in the print–out. Note: Print Everyth.
Reset Print
Interruption of a printing On the main print selection page, the ”Reset Print” softkey interrupts any printing that is taking place.
Line–, Sheet Advance To execute a line–feed, or form–feed on the printer, first select the softkey for printer functions, then the corresponding key for the function.
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4.5.11.4.4 Selection of Pages to be printed
With actuation of the softkeys ”Page select” in the softkey line of the screen page ’84 PRINTING’, the selection window with the screen pages is opened and the softkey line changed over.
Single pages: Use the cursor or the shuttle wheel to move up and down the window and select a page. Note: increment
The window can be paged forward and back with the softkeys ”increment” and ”decrement”.
decrement Print Page
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Initiate printing with the softkey ”Print Page”.
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Selection of Pages to be printed – continuation A selection of pages: Use the cursor or the shuttle wheel to move up and down the window and select a page. After each page press the E=Enter key and check that the page appears in the upper right of the display. Note: This method allows the operator to print up to 10 pages in one operation. Close the window with page back.
Manual Report
Reset Report
Check that the programme option for pages is on, then press the softkey for ”Manual Report” to start printing. Note: The pages will be printed in the order they were selected. The value given for lines per page, max 99, determines the number of machine pages per printed side. Cancel of pages in the selection box
Cancel Pages
Cancel Pages
Cancel Everyth. Cancel Everyth.
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The pages in the selection box can be removed by pressing the softkey ”Cancel Everyth.”.
Similarly, a single page can be removed from the print queue by highlighting it with the cursor and pressing the ”Cancel Pages” softkey.
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4.5.11.5
Operation
Screen page ”87 PASSWORD” – Allocation and Configuration of a User Chip–Card
By pressing the softkey ”Password” in the softkey line on the screen page ’80 PAGE LAYOUT’ chap. 4.5.11.1, the page ’87 PASSWORD’ is displayed.
Password allocation is carried out under the access level of the so– called supervisor with his own 8 digit super password. Only after typing in this super password the screen page ’87 PASSWORD’ will be available to accept the allocation of 5 digit passwords for standard operators. It is possible to allocate up to 50 passwords with up to 4 different access levels for the standard machine operators.
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4.5.11.5.1 Password – Allocation How to allocate passwords with access codes: Password – Allocation for User with Access level 1...4 Press the decimal point ”.” Type in the 8 digit super password (it will not appear on the display) Press the E = Enter key The password page ’87 PASSWORD ’ is now available for modification. PASSWORD .1 12388 .
KEY 4
PASSWORD .1 12388 .
KEY 4
Proceed by means of cursor keys or by turning the shuttle wheel to the required input position of the password. Make up a 5 digit operator password and press the E = Enter key Select the access level with cursor or by turning the shuttle wheel, feed in corresponding level (1–4) and take over with Enter. Note: In the same way other passwords can be set or overwritten Press the decimal point key ”.” followed by the C = Cancel key, and access to the password page is blocked. Password – Allocation for Super – User
SUPERUSER: 12345678
The super password can only be changed by the supervisor with the original 8 digit password, as follows: Press the decimal point ”.” Type in a new 8 digit super password (it will not appear on the display, but try not to forget it !) Press the E = Enter key The operating values, which can be used only with password level 2 and higher, are listed in the operating instructions and, if available, in the Help disk under chap. 4.3.1. Call up the Help – disk on page ’0 MAIN MENU’ and select chap. 4.4.3 ”Access/ Password Levels”.
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4.5.11.5.2 Configuration of a User Chip–Card
With actuation of the softkey ”USER card” in the softkey line of the screen page ’87 PASSWORD’, the input window for USER password and access level is opened and the softkey line changed over.
Insert a user card Proceed by means of cursor keys or by turning the shuttle wheel to the input position of the password. Make up a 5 digit operator password and press the E = Enter key Select the access level with cursor or by turning the shuttle wheel, feed in corresponding level (1–4) and take over with Enter.rechende Ebene (1–4) eingeben und mit Enter übernehmen. Store card
The inputs are stored on the card by actuation of the softkey ”Store card”. Close the window with the softkey ”return”.
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4.5.11.6 Screen page ”85 SERVICE PAGE” 4.5.11.6.1 Screen page ”85 SERVICE PAGE” – Indication of Operating hours, Lubrication and Machine cycles, as like inspection diagram
By pressing the softkey ”Service” in the softkey line on the screen page ’80 PAGE LAYOUT’ chap. 4.5.11.1, the page ’85 SERVICE PAGE’ is displayed.
This page show information relating to the following: Operating hours for SPS (CPU machine controller) Ergocontrol (NC4 console) Barrel heating switch–on time Pump run time Lubrication (only on toggle–lock machines). The set values are automatically calculated for machine size. Machine Cycle The number of machine cycles. These parameters for logging of operating hours will be set–up by Demag Ergotech during or before machine commissioning.
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Screen page ”85 SERVICE PAGE” – Indication of Operating hours, Lubrication and Machine cycles, as like inspection diagram Inspection diagram On machines with ”GA/ZE 488 Maintenance display” the remaining time before the next inspection is also indicated by a time bar. It starts with 4 green bars, which decrease from left to right by a fixed increment each cycle. Each bar corresponds to three months or 1.5 million cycles. Every 500 hours an info–window appears (on current page) in which the user is required to carry out maintenance work according to the manual, the softkey line will then change. The actual pump running hours are also displayed in the info–window.
Press the ”Enter” softkey in order to be reminded again; the info window will close and the softkey line changed back. Note: After 10 minutes the info window is opened again.
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Screen page ”85 SERVICE PAGE” – Indication of Operating hours, Lubrication and Machine cycles, as like inspection diagram
Press the ”OK” softkey when the service work has been carried out. The info window is closed and the softkey line changed back. Note: Access is only possible from password level 5. Note: Work carried out by the user can be listed on screen page ’852 MAINTENANCE PLAN’ (see chap. 4.5.11.6.3). When the end of the bars has been reached the operator is asked every 20 minutes by a message ”carry out inspection –––> Demag Service’ to call up Demag Plastics Group Service; at the same time a fifth, yellow bar starts, which also reduces incrementally.
The bar represents 500 000 cycles. Note: The inspection should be carried out before the fifth bar is used up. Maintenance work carried out is confirmed by the Demag Plastics Group engineer in screen page ’851 MAINTENANCE PROGRAM’ (see chap. 4.5.11.6.2). Note: If the end of the fifth bar is reached without the inspection being carried out a sixth, red bar appears. In addition the message ”Service –––> Demag Plastics Group” appears every 30 minutes.
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4.5.11.6.2 Screen page ”851 MAINTENANCE PROGRAM” – Display of inspection work
By pressing the softkey ”Mainten.– programme” in the softkey line on the screen page ’85 SERVICE PAGE’ chap. 4.5.11.6.1, the page ’851 MAINTENANCE PROGRAM’ is displayed.
On this Page all inspection work to be carried out is listed. When the user is requested for the first time to call Demag Plastics Group Service, the work to be done is displayed and, in the ”ON” column, the date of the first request. Note: Completion of the work can be confirmed only by a Demag Plastics Group Service technician. The completion date is recorded in the ”OFF” column and the name of the technician in the ”Done by” column.
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4.5.11.6.3 Screen page ”852 MAINTENANCE PLAN” – Recording maintenance work
By pressing the softkey ”Mainten.– plan” in the softkey line on the screen page ’85 SERVICE PAGE’ chap. 4.5.11.6.1, the page ’852 MAINTENANCE PLAN’ is displayed.
Up to 16 items of completed work together with the date and the name of the person carrying them out can be entered via the Ergocontrol keyboard. Note: Access is only possible from password level 5.
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Screen page ”852 MAINTENANCE PLAN” – Recording maintenance work – continuation Typing the text Move the cursor to the input line Press the ”ABC” key on the console to activate all the ASCII character keys. During typing the keys for Manual operation are blocked.
”Shift”
”ABC”
Use the shift key for capitals.
End a line with the E=Enter key
Use the Clear key to delete. The rest of the line is then shuffled left.
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4
Screen page ”86 AMENDMENT REPORT LOG” – Indication and Dropping of changes
By pressing the softkey ”Amendment Report” in the softkey line on the screen page ’80 PAGE LAYOUT’ chap. 4.5.11.1, the page ’86 AMENDMENT REPORT LOG’ is displayed.
This function keeps a record of any adjustments to the machine settings on the Ergocontrol and displays them in a compiled report. It can be switched on and off as desired using the page ’83 SETUP’. When the function is on, an operator making any adjustment to a setting is required first to typing the reason for the adjustment, only then can the adjustment actually be made. The text for each adjustment reason can be modified to the operators requirements on the page ’83 SETUP’ chap. 4.5.11.2.
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Amendment report – continuation Example Choose the parameters which need to be change by selecting the page, and then moving the cursor down to the appropriate input field Type in the new value and confirm by pressing the E = Enter key A super–imposed window appears with a selection of adjustment reasons. Use the cursor to choose the one that applies in this instance Press the E = Enter key to confirm the reason, and the new value is accepted by the system The ”amendment report” page contains the following information: Changes: The number of the parameter that was changed. inkrement
dekrement
If there are more than 15 changes, then the arrow keys (increment/decrement) can be used to scroll up and down the list to a maximum of the 60 last entries. 1. Field: Reason for adjustment in clear text 2. Field: The parameter that has been changed in clear text 3. Field: The original value for the parameter 4. Field: The new adjusted value for the parameter 5. Field: Password Index No. (but not the password) 6. Field: Time and date of the adjustment Note: After selection of a parameter with the cursor keyboard or by turning the shuttle wheel and take–over with key ”E” (Enter) the screen page, in which the amended parameter is located, is opened. A double arrow on a dark background indicates the amended parameter. Dropping of Parameter / PG–Switch changes
Dropping
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After selection of the change with the cursor keyboard or by turning the shuttle wheel and pressing the softkey ”Dropping” the selected change is cancelled and entered as a new change.
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4.5.12
Function – Group Service – Description of the Screen Pages
Service 4.5.12.1
4
Press Function Selection Key to select screen page ’90 FUNCTION CONTROL’.
Screen page ”90 FUNCTION CONTROL”
It is most important that in the unlikely event of service being required for the system, a quick and all–round view of the diagnostics is provided. On this page the outputs are listed and shown in inverse graphics when they are active. The voltage supplied for allocated pressure and speed is represcuted by p... and v...
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4.5.12.2
Operation
Screen page ”91 STATUS TEST” – Bit Control
By pressing the softkey ”Bit Control” in the softkey line on the screen page ’90 FUNCTION CONTROL’ chap. 4.5.12.1, the page ’91 STATUS TEST’ is displayed.
up
down
Station +
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Station –
This page is only for the use of Demag service personnel. It allows the engineer to test the status of all the software flags and data bits either in the SPS machine CPU control or in the NC4 console, without resorting to connecting an external programming unit. After selection of an address with the cursor keys up/down the corresponding address can be increased or reduced by 1 by the softkeys ”address +” and ”address –”. In addition turning the shuttle wheel can change the address.
The selection of CAN station (SPS) and local (ergocontrol) is made via the softkeys ”Station +” and ”Station –”.
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4.5.12.3 Screen page ”COMMISSIONING” 4.5.12.3.1 Screen page ”96 COMMISSIONING” – Dry cycle, Lubrication test, Commissioning , Optimising of cyclinder heating, Pump and Stroke commissioning
By pressing the softkey ”Commissn.” in the softkey line on the screen page ’90 FUNCTION CONTROL’ chap. 4.5.12.1, the page ’96 COMMISSIONING’ is displayed.
This screen page contains all the PG switches for commissioning the clamp and injection unit IU1 Programme option ”Lubrication test” can be operated from password level 1 and above. Programme options ”Dry cycle”, ”Cylinder heating” and ”Hotrunner heating” can be operated from password level 2 and above. All remaining functions can only be operated from password level 4 and above.
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Screen page ”96 COMMISSIONING” – continuation The function ”Test oil lubrication” is only available on toggle–lock machines. The dry cycling operation only runs in Manual operation mode. The functions available under dry cycling are: Mould open and close Hydraulic ejectors forward and back Cores in and out Injection unit forward and back In order to commission the machine functions, the machine must be in Set–up mode and the commissioning programme option selected. Note: After finishing commissioning the ”Commissioning” PG switch must be reset manually. The programme option switches for optimizing the various operations, are reset automatically after each operation has been optimized.
4.5.12.3.1.1 Optimisation of cylinder heating, hot runner– and mould heating The best heating control for these three systems is achieved through self–optimization, or adaptive control. Optimisation occurs in 2 stages: Preheating Starting requirements: Final set values must be at least 65C higher than actual value. If needed zones to be cooled down. With hot runners start–up temperature must be set at 0. Sequence Set preheating set values = actual values + 5C (at least 50C at cold starting). Switch heating on Wait until actual values = preheating set values and ED values (operating factor) are approx. 5%. Switch heating off Note: If the error message ”Cylinder heating is not optimised” appears on the screen, optimisation takes place without preheating.
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Optimisation of cylinder heating, hot runner– and mould heating – continuation Automatic optimisation Starting requirements: Heating switched off Final set values must be 60C higher than actual value. (exception: feeding zone) With hot runners start–up temperature should be set at 0. Enter final set values (= process set temperatures, 40C for feed zone) Sequence Set PG switch ”Set up control”. Set PG switch ”Cylinder heating” or ”Hot runner heating” or ”Mould heating”. An error message will appear on the Ergocontrol – for example,”Cylinder heating is being optimised”. Switch heating on Wait until the error message is cancelled. Note: During optimisation the symbols ” hydr.–block or tank line
Injection unit, non – operater side
2
Hydr.–block ––> hydr.–block
3
Hydr.–block ––> injection block
4
Machine bed ––> movement cylinder
5
Hydr.–block ––> hydr. oil cooling unit
Front face Injection unit
6
Machine bed division injection unit / clamping unit (only on Ergotech 420/800 and 500/900 up to 2000/1800)
Clamoing unit, non – operater side
7
Machine bed ––> hydr.–block on anchor platen
8
Hydr. block on anchor platen ––> hydr.–block on moving platen
9
Anchor platen ––> clamping cylinder (only Plastics Group 125/475 up to 350/810 and 420/810)
10
Directional valve 2SH4 for mould safety mechanismus (only Plastics Group 125/475 up to 350/810 and 420/810)
11
Anchor platen ––> clamping cylinder (only Plastics Group 125/475 up to 350/810 and 420/810)
Clamping unit, operater side
BA027.01.1.en
Maintenance
6.13
Maintenance for the electrical screw drive
6.13.1
Maintenance for the electrical screw drive – Demag modular 125/475 up to 350/810 and 420/810 Oil Change for Electrical Screw Drive– Demag modular 125/475 up to 350/810 and 420/810
6.13.1.1
oil feed opening (non–operator side)
6
oil feed opening
chain box
oil level sight gla
oil level sight glass (operator or non–operator side)
gear (from IU 1450)
oil drain plug oil drain plug
Picture 131: Oil Change for Electrical Screw Drive
See lubrications table chap. 6.3 for appropriate lubricanting oil Frequency of change – see Maintenance Plan chap. 6.3 Quantity of oil : see Table Attention! Oil change has to be done under hot running condition of the gear Note: Pollution control: The old oil must be properly disposed of. Return to oil supplier etc.
BA027.01.1.en
6-33
6
Maintenance
Oil Change for Electrical Screw Drive – Demag modular 125/475 up to 350/810 and 420/810 – Continued Note: A gear is only available from injection unit IU 1450 upwards. Gear – Oil filling
Chain box – Oil filling
ltr.
ltr.
IU 320
–
2,0
IU 440
–
2,0
IU 610
–
1,6
IU 840
–
1,6
IU 1450
2,0
5,2
IU 2300
2,5
3,9
IU 3300
2,5
2,4
Injection unit
Table 42: Quantity of oil filling
6-34
BA027.01.1.en
Maintenance
6
6.13.1.2
Change of Chain and Sliding Element (Chain tightener) Demag modular 125/475 up to 350/810 and 420/810 6.13.1.2.1 Change of Sliding Element (Chain tightener) Demag modular 125/475 up to 350/810 and 420/810
d
e
b a c
f
Picture 132: Change of sliding element
Frequency of change – see Maintenance Plan chap. 6.2 Sequence discharge oil from chain box after unscrewing screws a remove cover b of chain box. unscrew lock nuts c and unscrew screws d till chain tightener is totally relieved unscrewing screws e and shove sliding element f off after change of chain (see cap.6.13.1.2.2), refitting in reverse sequence
BA027.01.1.en
6-35
6
Maintenance
6.13.1.2.2 Change of Chain – Demag modular 125/475 up to 350/810 and 420/810
k g
h
i
k
Picture 133: Change of chain
Frequency of change – see Maintenance Plan chap. 6.2 Removal of the chain Note: Before carrying out of chain change the chain tightener has to be totally relieved (see cap.6.13.1.2.1). Loosen securing pin g and remove rivet h Move chain link i and k forward, then remove chain Refitting of the chain Put the chain around the gear wheel so that both ends meet on the large wheel and interlock Insert chain link i+k together intao the plate hole
6-36
BA027.01.1.en
Maintenance
6
Change of Chain – Continued Attention! Be careful to ensure correct position of chain links (see picture 3). Incorrect layout could result in erratic movement and in certain circumstances a brocken chain. Subsequently knock rivet h and secur with securing pin g after refitting of sliding element tighten chain (see Cap. 6.13.1.2.1) mount chain box cover b and secure with screws a fill oil (see Cap. 6.13.1)
BA027.01.1.en
6-37
6
Maintenance
6.13.2
Maintenance for the electrical screw drive Demag modular 420/800 and 500/900 up to 2000/1800 6.13.2.1 Oil Change for Electrical Screw Drive Demag modular 420/800 and 500/900 up to 2000/1800 6.13.2.1.1 Oil Change for Electrical Screw Drive Demag modular 420/800 and 500/900 up to 2000/1800 up to injection unit IU 3300
oil feed opening
chain box
oil level sight glass
oil drain plug
gear (from IU 840) Picture 134: Oil Change for Electrical Screw Drive
See lubrications table Chap. 6.3 for appropriate lubricanting oil Frequency of change – see Maintenance Plan Chap. 6.2 Quantity of oil : see Table Attention! Oil change has to be done under hot running condition of the gear Note: Pollution control: The old oil must be properly disposed of. Return to oil supplier etc. Note: A gear is only available from injection unit IU 840 upwards. Injection unit IU 1450 Gear–/chain box – Oil filling
ltr.
8,2
IU 2300 9,4
IU 3300 9,4
Table 43: Quantity of oil filling
6-38
BA027.01.1.en
Maintenance
6
6.13.2.1.2 Oil Change for Electrical Screw Drive Demag modular 420/800 and 500/900 up to 2000/1800 from injection unit IU 6400 oil feed opening
oil level sight glass
oil drain plug
Picture 135: Oil Change for Electrical Screw Drive
See lubrications table Chap. 6.3 for appropriate lubricanting oil Frequency of change – see Maintenance Plan Chap. 6.2 Quantity of oil : see Table Attention! Oil change has to be done under hot running condition of the gear Note: Pollution control: The old oil must be properly disposed of. Return to oil supplier etc. Injection unit
Gear–/chain box – Oil filling
ltr.
IU 6400
IU 9500
IU 11500
IU 16000
43
63
130
11600
Table 44: Quantity of oil filling
BA027.01.1.en
6-39
6
Maintenance
6.13.2.2
Change of Chain and Sliding Element (Chain tightener) Demag modular 420/800 and 500/900 up to 650/1000 6.13.2.2.1 Change of Sliding Element (Chain tightener) – Demag modular 420/800 and 500/900 up to 650/1000 Injection Unit IU 1450 – IU 3300
e
c d b
f
a
Picture 136: Change of sliding element
Frequency of change – see Maintenance Plan Chap. 6.2 Sequence discharge oil from chain box after unscrewing screws a remove cover b of chain box. unscrew screws c and unscrew screws d till chain tightener is totally relieved unscrewing screws e and shove sliding element f off after change of chain (see Chap. 6.13.2.2.2), refitting in reverse sequence
6-40
BA027.01.1.en
Maintenance
6
6.13.2.2.2 Change of Chain Demag modular 420/800 and 500/900 up to 650/1000 – Injection Unit IU 1450 – iu 3300
g
h
k
k
i
Picture 137: Change of chain
Frequency of change – see maintenance plan Chap. 6.2 Removal of the chain Note: Before carrying out of chain change the chain tightener has to be totally relieved (see Chap. 6.13.2.2.1). Loosen securing pin g and remove rivet h Move chain link i and k forward, then remove chain
BA027.01.1.en
6-41
6
Maintenance
Change of Chain Demag modular 420/800 and 500/900 up to 650/1000 – Injection Unit IU 1450 – iu 3300 – – Continued Refitting of the chain Put the chain around the gear wheel so that both ends meet on the large wheel and interlock Insert chain link i+k together intao the plate hole Attention! Be careful to ensure correct position of chain links (see picture). Incorrect layout could result in erratic movement and in certain circumstances a brocken chain. Subsequently knock rivet h and secur with securing pin g tighten chain (see Chap. 6.13.2.2.1) mount chain box cover b and secure with screws a fill oil (see Chap. 6.13.2.1.1)
6-42
BA027.01.1.en
Maintenance
6.13.3
6
Servicing the Electric Motor – screw drive For servicing electric motor –4M1 for the electrical screw drive see separate operating manual issued by electric motor manufacturer. Attention! Before carrying out any maintenance work on the electric motor, the machine must be switched off on main switch –1QO. Do not switch motor on when safety guard is removed from fan wheel – there is serious risk of injury!
6.13.4
Change of Fan – Frequency Converter For changing of fan for the frequency converter see separate operating manual issued by frequency converter manufacturer. Attention! Before carrying out any maintenance work on the frequency converter, the machine must be switched off on main switch –1QO. On clearing the secondary circuit capacitor there is still a danger for 5 minutes that voltage could be present. Attention! Maintenance for electrical equipment should only be executed by a qualified electrician.
BA027.01.1.en
6-43
6
6.14
Maintenance
Servicing the Electric Motor – pump drive For servicing electric motor –1M1 for the pump drive see separate operating manual issued by electric motor manufacturer. Attention! Before carrying out any maintenance work on the electric motor, the machine must be switched off on main switch –1QO. Do not switch motor on when safety guard is removed from fan wheel – there is serious risk of injury!
6-44
BA027.01.1.en
Maintenance
6.15
6
Replacing a battery Attention! Batteries should only be replaced by a qualified electrician. The machine must be switched on when the battery is changed, otherwise the control system will lose the setting data and programmes.
6.15.1
Replacing the battery in the Ergocontrol
d b a
c Back of the Ergocontrol Picture 138: Replacing the battery in the Ergocontrol
See Maintenance Plan chap. 6.2 to establish how often the battery should be replaced. Switch machine on Release screws a and remove battery b Disconnect plug c Undo cable clip d Attach new battery b to cover using cable clip Connect plug c Replace battery and tighten screws a
BA027.01.1.en
6-45
(SO)
(SE)
(–X19)
6-46 –F1 –H1 –F2 –H2 –F3 –H3 –F4 –H4 –F5 –H5 –F6 –H6 12 –X1.7
–X1.3 –X1.1 –X1.2
–1A3 1 1 6 8 1 1 6 41 1 6 –H13 1
plug–in station 1
112 plug–in station 5
1 1
–X1.10
–X1.9
–1A14 1
10
8 1
25 12 1
–1A71
ZE
–1K41 –4K20 –2K66
–1K49 –2K919
C229...C234 C297, C298 C523,C661 –3K1 C750,C751,C752
C546
0.25 15 144.4 30
CIC 011
STATIONCIC 45011 STATION 46 STATION 47 STATION 48 STATION 49 STATION 50 STATION 51 STATION 52 STATION 53
80x80x735
–X2.11 –X2.10 –X2.8 –X2.7 –X2.5 –X2.3 –X2.2 –X2.1 –X2.12 –X2.4 –X2.9 –X2.6 –X2.18–X2.17 –X2.16 –X2.15 –X2.14 –X2.13 plug–in station 6 –X1.20 –X1.19 –X1.18 –X1.17 –X1.16 –1K11 plug–in station 7 –1K12 –X1.21 –X1.22
plug–in station 4
plug–in station 3
plug–in station 2
–X1.8
0.25 733.1 80
0.25 100 780 150
C523
C562
C542
C562
–1K21
0.25 15 69 30
–1K5.2
0.25 15 498.8 35
–X5.1 –X5.2 (ZE) –X6.1 (ZE) –X6.2 (ZE) –X7.1 –X7.2 (SO) –X8.1 (ZE) –X8.2 (SO) –X9.1 (SO) –X9.2 (SO) –X10.1 (SO) –X24.2 (ZE) –1X14.3
–X1.1 –X1.2/.21 (ZE) –X1.3 –X2.1/.11 (ZE) –X2.2 (ZE) –X3.1 –X3.2 –X3.3 (SO) –X4.1 (ZE) –X4.2 (ZE) –X4.3 (SO) –X4.4 (SO) –1X14.2
6.15.2
plug–in station 0
–X1.6 –X1.5 –X1.4 –H9 –2K15–H20 –H8 –2K14–H19 –H15 –1K17 –1K10 –H14 –X1.13 –6K31–X1.12 –1K16 –X1.11 –X1.15 –6K33 –X1.14 –1K8
EEPROM 1EN201–unit 1 –1A14.65 4 1 onboard 4 10 1–1A14.05 1 –X2.19 61 1 1 –H7 EN201–LED OK= 41 81 10 1 1 8 8 12 12 10 1 1 1 ON 11 1 10 8 12 41 81 10 4 –1A14.05 070 392 133 –1A14.02 –1A14.03 65 –1A14.04 –1A14.06 –1A14.07 1 1 1 1
plug–in station CPU
0.25 80 40 434
100x150x780
6 Maintenance
Replacing the battery in the machine control system Control cabinet Electrical distribution box –X19
C556
80x60x1380
80x40x435
–1A72
(EE) SO
c
a
b
Picture 139: Replacing the battery in the machine control system
See Maintenance Plan chap. 6.2 to establish how often the battery should be replaced.
Switch machine on
Open door of control cabinet or door on electrical distribution box –X19
Take off cover or lift up lid
Remove battery b
Insert new battery and replace cover
Close control cabinet door or door on electrical distribution box –X19
BA027.01.1.en
Maintenance
6.16
6
Cleaning – De–scaling the Water Cooling System Frequency of cleaning depends on the hardness of the cooling water.
6.16.1
De–scaling the Oil Cooler, Screw Cylinder Feed Zone and electrical drive for screw. The oil–cooling system, barrel throat and electrical drives for screw can be de–scaled using a industrial fast de–scaler unit connected between the cooling water inlet and outlet. Descaling agents Use an ordinary commercially available descaler based on sulphamic acid, formic acid or acetic acid with a corrosion preventative. Attention! The manufacturer’s instructions as to concentration and duration of application must be followed. The Health and Safety instructions of the descaler manufacturer must be followed without fail. Attention! Strong acids, such as hydrochloric, sulphuric or nitric acids must not be used, as they will damage the cooling system. Closed cooling system With a closed cooling circuit with normal additives, descaling is not usually required. The max. operating pressure is 7 bar. After de–scaling, re–connect up the cooling water inlet and outlet.
BA027.01.1.en
6-47
6
6.16.2
Maintenance
De–scaling the Mould Cooling System
Picture 140: Cleaning the Sight Glass Tubes
Sequence Unscrew the upper cap using key. Clean from above using a brush. If necessary pull the pipe out upwards. Push the pipe back down into position, and screw down the cap.
6-48
BA027.01.1.en
Maintenance
6.16.3
6
Cleaning the filter screen in the water filter 2FT20 (cooling water inlet)
k m Picture 141: Water filter for cooling water inlet
Frequency of cleaning see chap. 6.2 Sequence Shut off water inlet to the machine. Unscrew plug m. Filter screen k is to be cleaned with pressure air. Screw on plug m. Open water inlet again.
BA027.01.1.en
6-49
6
6.16.4
Maintenance
Cleaning the filter screen in the water filter 1FT17 (cooling water inlet) Demag modular 420/800 and 500/900 up to 2000/1800 with electric screw drive
b
a Picture 142: Water filter for cooling water inlet
Frequency of cleaning see chap. 6.2 Sequence Open valve a and allow the water to flow for about a minute (e.g. into a bucket). Close the valve again. Note: Change filter b if necessary.
6-50
BA027.01.1.en
Maintenance
6.17
6
Maintenance/Cleaning of Screw Cylinder Note: Do not clean any more frequently than is absolutely necessary! When changing from one material to another, it is recommended to keep to the correct sequence for colour– or material– change. See chap. 5.3.3. Carefully planned colour sequences can save a lot of cleaning work. The decision on whether to clean or not is usually made after 20–30 shots following colour changes. With an open nozzle and SFS flight screw tip fitted, the colour change should take place after only 3–7 shots. It takes longer when an RSP non–return valve and SVN or SVH nozzles are used. The choice between partial or total cleaning depends on the type of contamination.
6.17.1
Partial Cleaning Operation. Even after the screw has undergone a thorough self–cleaning process, the screw tip and space immediately behind the nozzle opening is often a particular trap for contamination and material residue, especially for SNV or SVH nozzles. A consistant streak may occur in the same place on the mouldings as a result of colour residue being drawn through nozzle channels or as a result of the gating in the mould. If the residual melt is otherwise perfect, then it is usually sufficient to concentrate cleaning in area of the seals, aperture and sealing faces on the cylinder head, together with a check on the screw tip.
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work especially on a heated screw cylinder!
BA027.01.1.en
6-51
6
6.17.2
Maintenance
Complete cleaning operation If moulding contamination is uneven and finely dispersed, it has probably developed mostly in the area of the screw, the non–return valve or the cylinder head. A complete cleaning operation is required! Particularly difficult areas include the sealing faces between the screw cylinder and nozzle, and between the screw and screw tip. Such contamination occurs if there is insufficient contact pressure on the flat sealing faces, or as excess lubricant escapes from the thread.
6.17.3
Charring and colour changes on the moulding Compressed, trapped air is the most frequent cause of charring or black spots occurring at the furthest point on the flow path during the final mould filling stage. The cause is either incorrect design, gating or insufficient mould venting but not contamination of screw cylinder.
6.17.4
Preparatory Steps If the screw cylinder has to be cleaned, it must always be purged and removed from the machine, see chap. 5.3.4. Note: Never allow a full screw cylinder to cool down. Squirt as much melt as possible through the nozzle out into the open. Do this at a moderate injection speed. Attention! If ZE ”Fast Injection with Accumulator” is fitted, this equipment must be switched off – (serious risk of injury).
Attention! A face mask and protective gloves must always be worn when undertaking cleaning and maintenance work, especially on the heated screw cylinder!
6-52
BA027.01.1.en
Maintenance
6
Preparatory Steps – continued If a moulding compound has been processed which is difficult to clean out, such as polyamide, polycarbonate etc., purge the cylinder. Then plasticise a material such as acrylic, polystyrene or polyethylene, and purge the cylinder again. Check the temperature of the screw cylinder before changing the material. If possible, screw cylinders should be cleaned by experienced personnel. If training is required, please contact our training department. Cleaning the cylinder may give rise to foul–smelling gases causing inconvenience to personnel in the work area. Also some moulding compounds give off fumes at very high temperatures which can accelerate corrosion to any polished machine parts. For this reason, the cleaning area should be separate from the machine operating area. It should be well ventilated.
6.17.5
Cleaning the heated screw cylinder Attention! If the screw cylinder is heated to excess, gasses can form which can force the screw out of the cylinder – (risk of injury). This is a particular danger if the cylinder has not been purged – (procedure described above). Under supervision, heat up the dismantled screw cylinder using all heater bands. Remove the nozzle heater band after approximately 15 min heating time and unscrew the nozzle. Before releasing the heater bands, disconnect the power – remove the plug! Reheat the screw cylinder under supervision, until the screw can be gently rotated. Watch out for materials that decompose with heat. Ventilate the area well. Remove heater band from cylinder head. Unscrew cylinder head. To aid colection of any residual melt, draw the screw out with movements back and forth between the fixed platen and the stop on the screw coupling.
BA027.01.1.en
6-53
6
Maintenance
Cleaning the heated screw cylinder – continued Reheat the cylinder until the excess plastic melts away from the cylinder wall. Wind a cloth around a wooden rod and remove residual melt. Attach to this a round wire brush, approx. 2mm larger the cylinder bore, with a flexible, rotating shaft (e.g Biax device), and clean the cylinder. Then polish with emery cloth, 240 to 280 grade. The emery cloth should be wound around the wire brush. Attention! When rubbing down, do not round off the sharp edges on the flat sealing faces. To avoid wearing the sealing edges, insert the brush into the cylinder before switching on the rotating shaft. Clean threads with wire brush. If the cylinder is then to be put into stock, treat all parts with anti– corrosion spray. Before reassembling, degrease and treat all threads with HSC paste.
Attention! Temperature on all parts must be balanced for parts assembly!
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work, especially on a heated screw cylinder!
6-54
BA027.01.1.en
Maintenance
6.18
6
Cleaning the screw Attention! Avoid impacts and shocks when working with the screw (Danger of breaking). Any melt residue still left on the screw, that cannot be otherwise removed should be burnt off with the weakest possible flame. We recommend the use of a propane burner. Attention! Never allow the screw to anneal. Use the gas burner with extreme caution. Note: Arrange for good ventilation because of the resulting fumes. Do not heat the screw piecemeal, heat large areas uniformly. Rotate the screw evenly at the same time. Unbalanced heat stress causes screw distortion. Nor should the screw exceed 400C on the flights, as this affects its hardness and wear resistance. Caution on screws with non–return valve fitted. The thin–walled check ring heats up much faster. Clean the screw afterwards with a wire brush. Polish screw profile and surface with emery cloth, 240–280 grade. With a flame, carefully burn off any residual material from the internal screw thread (left–hand thread).Then thoroughly clean the thread with a wire brush. Use only HSC – Paste to lubricate the thread when screwing the screw tip onto the screw. Attention! Temperature on all parts must be balanced for parts assembly!
BA027.01.1.en
6-55
6
Maintenance
Cleaning The Screw – continued Attention! Under no circumstances should any sort of grease or oil be used to lubricate the thread. These lubricants carbonize at high operating temperatures. Any such residue in the thread flights can bond the screw tip. Attention! When assembly take care of position of check ring (see chap. 6.19).
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work, especially on the heated screw cylinder!
6-56
BA027.01.1.en
Maintenance
6.19
6
Cleaning the Screw Tip
Picture 143: Releasing the Screw Tip
Clamp screw tip b horizontally into the vice with its V–shaped brass jaws m (tool kit). Do not damage check ring when RSP non–return valves are fitted. Support screw c on shaft f and apply spline key e (tool kit). Heat up screw and screw tip along the threaded length of the screw tip to max 400C. The screw tip can be released by gently hammering on spline key e. Caution – left–hand thread!
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work, especially on a heated screw cylinder!
BA027.01.1.en
6-57
6
Maintenance
Cleaning the Screw Tip – continued Clean the screw tip, check– and pressure– rings with a wire brush after releasing them from the screw and polish with an emery cloth, 240–280 grade. Thoroughly clean screw tip thread with a wire brush and treat with HSC – Paste. Attention! Under no circumstances should any sort of grease or oil be used to lubricate the thread. These lubricants carbonize at high operating temperatures. Any such residue in the thread flights can bond the screw tip. Attention! When assembly take care of position of check ring
Picture 144: Position of check ring
Attention! Temperature on all parts must be balanced for parts assembly!
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work, especially on a heated screw cylinder!
6-58
BA027.01.1.en
Maintenance
6.20
Nozzle Cleaning
6.20.1
Open Nozzle
6
Using a flame, carefully burn off any residual melt from the nozzle. Then clean with the wire brush and polish with emery cloth, 240 – 280 grade. Do not round off edges on flat sealing faces! Attention! Temperature on all parts must be balanced for parts assembly!
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work, especially on a heated screw cylinder!
BA027.01.1.en
6-59
6
6.20.2
Maintenance
Needle Valve Nozzle SVN and Hydraulic Nozzle SVH If possible, clean nozzle when cold using copper or brass chisel and mallet. If cleaning cannot be done when the nozzle is cold, melt off the residual plastic in the seal with the nozzle attached. Do not melt off without the nozzle attached, which would damage the needle valve. Dismantle nozzle. If possible, remove excess melt from the valve housing when cold. Note: Risk of distortion on valve housing. Therefore, heat slowly and uniformly. Do not allow valve pin to anneal! Polish nozzle and valve housing with emery cloth – not forgetting the channels in the valve housing. Polish valve pin with polishing cloth. Do not disturb the snug fit. Use the wire brush to clean all threads thoroughly. Treat all nozzle parts with anti–corrosion spray, if they are to be put into store. Degrease, however, before refitting and treat all threads with HSC – Paste. Attention! Temperature on all parts must be balanced for parts assembly!
Attention! Always wear a face mask and protective gloves when undertaking cleaning and maintenance work, especially on a heated screw cylinder!
6-60
BA027.01.1.en
Maintenance
6.21
6
Cleaning the inspection panels on the safety guarding The inspection panels on the safety guarding can be cleaned using a mild cleaning agent and a soft cloth dampened with warm water. Note: Under no circumstances should hard or abrasive cloths or alcohol, diluting agents or molvents be used.
BA027.01.1.en
6-61
Table of contents
7
7
Fault Elimination, Fault Messages 7.1
Fault Elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.2
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
BA027.01.1.en
I
Fault Elimination, Fault Messages
7
Fault Elimination, Fault Messages
7.1
Fault Elimination
7
Faults that occur during machine operation are displayed with a text cause on the Ergocontrol. In the case of a setting or operating error, the solution is usually made apparant. The following screen pages serve as an aid: –
”90 FUNCTION CONTROL“ chap. 4.5.11.1
–
”91 STATUS TEST” chap. 4.5.12.2
Note: If the fault lies with hardware, please consult our Service Department. Attention! In order to ensure machine reliability during operation, use only genuine spare parts as replacements for faulty components. Please consult our Service department on the matter. Note: In the appendix to this operating manual you will find a complete set of hydraulic and electrical circuit diagrams, as well as a spare parts list for you machine.
BA027.01.1.en
7-1
7
7.2
Fault Elimination, Fault Messages
Fault Messages The fault messages are sorted alphabetically for easier orientation. In the explanatory text gou will find notes about possible reasons for the fault and how the fault can be rectified.
2SH9 defective *>
Check sensor on wire break and function and, if necessary, change sensor.
–2S216/7 made or defective Minimum or maximum mould height is achieved. Accumulator not charged or –4B9 defective *>
Check accumulator pressure
*>
If –4B9 is faulty, contact your Demag Ergotech Service Department.
Ancillary problem *>
An external unit registers a problem.
Automatic operation blocked PG–switch ”Automatic operation blocked” is actuated on screen page ’40 PRESELECT PROGRAMS’ and the machine is in automatic mode. The machine can only be operated in semi–automatic mode. Cable break The thermocouple on a heating circuit has failed. An Actual temperature of >700C is indicated for the relevant heating circuit; see screen page ’30 TEMPERATURES’, ’31 HOT RUNNER1–16’ and ’33 MOULD HEATING’. WARNING! the heating switches off. If program switch ’Control by wire breaks’ has been activated prior to the cable break, the heating will continue to function with a given regulating variable.
7-2
BA027.01.1.en
Fault Elimination, Fault Messages
7
Check carriage zero position Following a change of cylinder, nozzle or mould, the injection unit reference point must be set whilst the plasticising cylinder is hot; see screen page ’23 INJECTION UNIT’. Check ejector plate The limit switch for monitoring the ejector plate in the mould must be released during a cycle and then re–actuated. *>
Check and eliminate the reason for the alarm before restarting the cycle.
Central lubrication not complete *>
Check –2B222 for oil level in reservoir.
*>
Check pressure switch –2B225 (oil lubrication complete).
Clamp regulator OFF (No longer in use). Clamp regulator overrun or too high Maximum locking force has been exceeded during injection. Cold start prodection active You have activated blocking of start–up on screen page ’30 TEMPERATURES’.The pre–set time has not yet elapsed. The cycle can onlybe started when this time has elapsed. Cycle time overrun A fault has caused the duration of the cycle to extend beyond normal cycle time. *>
Check the reason using screen page ’2 ALARM DISPLAY’ Cycle time has been set too short.
*>
BA027.01.1.en
Note the normal dispersion of cycle time and enter a sufficiently large value.
7-3
7
Fault Elimination, Fault Messages
Cylinder heating is NOT optimised Cylinder heating must be optimised prior to cycle start. *>
The set temperatures for MH 1 – 3 or 4 and DH must be set on screen page ’30 TEMPERATURES’ at least 60C higher than the Actual temperatures; if necessary, allow the cylinder to cool down beforehand.
*>
Actuate switches for ”Commissioning” and ”Optimise cylinder heating” on screen page ’96 COMMISSIONING, and when the Actual temperatures have risen by at least 60C, the switches will be reset.
*>
Cycle start will operate when Set temperatures are reached.
Cylinder heating not controlled – cable break ”Cable break” switch has been set on screen page ’30 TEMPERATURES’. After a thermocouple has failed, the machine operates in this particular heating zone using the given percentage operating factor. The relevant heating zone can be seen on screen page ’30 TEMPERATURES’, because an incorrect Actual temperature of > 700C is indicated. *>
Decide whether you wish to complete job production in this mode or replace the damaged thermocouple straight away.
Cylinder heating not set No valid operating factor (ED) has been given for the controlled operation. Cylinder heating OFF The cylinder heating has not yet been switched on or has been switched off via a monitoring– or switch–off program.
7-4
BA027.01.1.en
Fault Elimination, Fault Messages
7
Core limit switch defective –
Though the core puller programme is switched off, core puller positions have been programmed and the dummy plug –2X120 (or –2X120 and –2X130 for ZE 233) is not plugged.
–
Core puller positions are not programmed and the inputs of the limit switches are not bridged for the nonprogrammed core.
–
The core puller programme is switched on, the core puller positions have been programmed for one core, the two limit switch inputs of this core are bridged and it shall not move in and out through time.
–
The core puller programme is switched on, the core puller positions have been programmed for one core. It shall move in and out through time. However, the limit switch inputs are bridged.
*>
The position of the limit switches of the cores is displayed on the screen page ’14 CORES’.
Cores direct In this mode a password level 2 operator can move the cores, the ejector and the mould directly without monitoring the core position. Before each movement check that this will not lead to any damage to the mould. *>
Move all cores into starting position before restarting the cycle.
Core not in basic position Movement of clamping unit not possible.
BA027.01.1.en
*>
The cores must first be moved into their ”OUT end position”. Switch on cores directly on screen page ’14 CORES’ (password level 2). Move cores out.
*>
Check the cause before restarting the cycle, if necessary increase pressure for ”Move cores out”, see screen page ’15 MOVE CORES OUT’ or check core pulling limit switch.
7-5
7
Fault Elimination, Fault Messages
Cores IN position not reached Movement of clamp unit not possible. *>
The cores must first be moved into their ”IN end position”. Switch on ”Cores direct” on screen page ’14 CORES’ (password level 2) – move cores in.
*>
Check the cause before restarting the cycle, if necessary increasing the pressure for ”Move cores in” – screen page ’14 CORES’ or check core pulling limit switch.
Dosing not complete The screw has not reached the set position. *>
Complete metering in manual mode, then change over again to semi– or fully–automatic operation.
Drive temperature –4M1 >90 % The motor is overloaded. The cycle is runnig on. *>
Reduce screw rotation.
*>
Set temperatures for cylinder heating set too low.
EEPROM error Only insert genuine Demag Ergotech EEPROMs. If an error message persists, contact your Demag Ergotech Service Department. Emergency OFF Machine has been switched off using EMERGENCY OFF switch *>
7-6
Eliminate the reason for the emergency stop, then release the EMERGENCY OFF switch and turn the machine on again.
BA027.01.1.en
Fault Elimination, Fault Messages
7
Faulty hardware The electric motor is running, even though the drive has been isolated via the safety chain. Or the control card on the variable delivery pump is faulty. *>
Check the relay for the electric motor and change relay, if necessary. If this does not eliminate the fault i.e. if the control card is faulty, call Demag Ergotech Service.
Guard door not closed The guard door on the clamping unit is not properly closed. *>
Open and close the guard door so that it engages properly.
*>
If this does not solve the problem, call your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
Handling OFF LINE Data exchange between the machine control system and the robot control system is faulty; the message ’OFF–LINE’ appears on the Ergocontrol. *>
Re–load robot program with robot boot disc.
*>
Re–load Ergocontrol with Ergocontrol boot disc.
*>
Re–load SPS with SPS boot disc. If, after this, the problem still exists, contact your Demag Ergotech Service Department.
Handling reference missing *>
BA027.01.1.en
Switch the machine to manual operation and using the ”Reference” key – (on the Ergocontrol, see operating manual chap. 4 ’Operation–mode–robot’) – move the robot into the basic position.
7-7
7
Fault Elimination, Fault Messages
Hot runner is not optimised Hot runner heating must be optimised prior to cycle start. *>
The Set temperatures for the runners in use must be set on screen page ’31 HOT RUNNER1–16’ at least 60 C higher than the Actual temperatures; if necessary, allow the runners to cool down beforehand.
*>
Actuate switches for ”Commissioning” and ”Optimise hot runner heating” on screen page ’96 COMMISSIONING’, and when the Actual temperatures have risen by at least 60C, the switches will be reset.
*>
Cycle start will operate when Set temperatures are reached.
Hot runner not controlled – cable break ”Cable break ...” switch has been set on screen page ’31 HOT RUNNER1–16’. After a thermocouple has failed, the machine operates in this heating zone using the given percentage operating factor.The relevant heating zone can be seen on screen page ’31 HOT RUNNER1–16’, because an incorrect Actual temperature of > 700C is indicated. *>
Decide whether you wish to complete job production in this mode or replace the damaged thermocouple straight away.
Hot runner not set No valid operating factor (ED...) has been given for the controlled operation. If controlled operation is required, an operating factor (ED) can be entered for the relevant heating zone(s); see screen page ’31 HOT RUNNER1–16’ in the ”Manual” column. Ejector coupling released Select screen page ’11 EJECTOR’; switch on ”Ejector” program switch. Move the ejector back manually and switch off the aforementioned program switch. Ejector forward stop not reached The ejector has not reached the pre–set position. *>
7-8
Please check for any mechanical obstruction and, if found, remove or alter ’Ejector forward’ position on screen page ’11 EJECTOR’.
BA027.01.1.en
Fault Elimination, Fault Messages
7
Ejector not back *>
Check on screen page ’11 EJECTOR’ whether ”Ejector” switch is on.
*>
Please check whether the switch –2B15 is properly wired in the core puller plug –2X12 and the signal is applied.
*>
In manual mode and with the mould open actuate the function keys ”Ejector forward” and ”Ejector back”. If this has not cancelled the alarm, the machine ejector is jammed with the ejector in the mould.
*>
Check whether the mould ejector system is in its furthest end position. If it is,
then enter an Actual value of +0.2 mm as a Set value for ”Ejector back stop” on screen page ’11 EJECTOR’.
If it is not,
again on screen page ’11 EJECTOR’ increase pressure Set value for ”Ejector back”, and in manual mode actuate ”Ejector forward” and ”Ejector back” in succession.
Hydr. mould safety problem Open and close guard doors; if this does not eliminate the problem *>
BA027.01.1.en
telephone your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
7-9
7
Fault Elimination, Fault Messages
Malfunction metering –4A4 / 4–U4 *>
If the fault notice still appears, switch off/on main switch –1Q0.
*>
If the fault notice still appears switching off/on main switch, then open the cabinet of the transformer and read the fault message on the display of the transformer and call Demag Ergotech Service.
*>
If a certain fault notice comes up repeatedly, this can be cancelled by actuation of the main switch, please inform your Demag Ergotech Service. Attention! The fault elimination for message ”Malfunction metering –4A4 / –4U4” should only be undertaken by an qualified electrician.
Motor overload Fault in machine setting, e.g.: *>
Monitoring of cycle time not activated or set too long (see screen page ’52 CONT. PROCESS CONTROL’).
*>
Set temperatures for cylinder heating set too low.
*>
Check whether the ventilation grid on the drive motor needs cleaning.
Motor overload –2Q1 *>
Please check the setting on the slipping clutch
*>
Please check whether the ventilation grid on the drive motor needs cleaning.
Mould heating is not optimised Mould heating must be optimised prior to cycle start.
7-10
*>
The Set temperatures for the runners in use must be set on screen page ’33 MOULD HEATING’ at least 60C higher than the Actual temperatures; if necessary, allow the runners to cool down beforehand.
*>
Actuate switches for ”Commissioning” and ”Optimise mould heating” on screen page ’96 COMMISSIONING’, and when the Actual temperatures have risen by at least 60C, the switches will be reset.
*>
Cycle start will operate when Set temperatures are reached.
BA027.01.1.en
Fault Elimination, Fault Messages
7
Mould heating OFF The heating has not yet been switched on or switched off via a monitoring or switch–off program. *>
Before restarting the cycle check the cause using screen page ’2 ALARM DISPLAY’.
Mould height adjustment Clamping force is set automatically. Please wait until this process is completed. Mould not in core movement position Cores cannot be started because the clamping unit is not in the programmed core pulling position. Move the mould into the core pulling position in ”Set–up–” or ”Manual mode”. If this is impossible, switch on ”CORES DIRECT”. Before each movement check that this will not lead to any damage to the mould. Mould not locked *>
Check mould height
Mould Open Stop not reached You have switched over to semi– or fully automatic operation, but before moving the clamping unit into its starting position. *>
Actuate the function key ”MOULD OPEN” by manual mode. Restart cycle. If you are using a mould which imposes mechanical limitation on the machine opening stroke, you have perhaps entered too high a Set value for ”Mould Open Stop”.
*>
In Set–up mode (typing mode) carefully move to the max. ”Mould opened ” position, and on screen page ’10 MOULD SETUP’ enter the Actual value less 0.5 mm as Set value for ”Mould Open Stop”. The mould cannot be opened by setting, manual, semi–automatic or automatic operation. Check the set value of the ”MOULD OPEN” position on the screen page ’10 MOULD SETUP’. If this is higher than the actual value,
BA027.01.1.en
7-11
7
Fault Elimination, Fault Messages
then actuate the function key ”OPEN MOULD” by manual operation. Mould safety time ’Mould closed’ position has not been reached within the set mould safety time, see screen page ’10 MOULD SETUP’. *>
Remove component or sprue.
*>
Increase mould protection force, screen page ’10 MOULD SETUP’.
*>
Increase mould protection time, screen page ’10 MOULD SETUP’.
Mould temp. unit 1 problem *>
Select screen page ’38 CONDITIONING UNIT’ to determine the cause of the problem.
Mould temp. unit 2 problem *>
Select screen page ’38 CONDITIONING UNIT’ to determine the cause of the problem.
No holding pressure (stroke, time, pressure) The criterion for change over from injection– to holding pressure is pre–selected on screen page ’20 PROCESS OPTIMIZATION’. The parameter selected for change over is monitored via the remaining change over parameters as soon as their set values reach >> 0.
7-12
–
Change over via stroke\volume is switched on, but change over point has not been reached.
*>
Cavities full or overfilled:
–
Shot volume too great and\or change over to holding pressure too late.
*>
Cavities not completely full:
–
Melt temperature too low ––> increase cylinder temperature (see screen page ’30 TEMPERATURES’).
–
Injection pressure too low (Actual value >= Set value) ––> increase Set value (see screen page ’20 PROCESS OPTIMIZATION’.
BA027.01.1.en
Fault Elimination, Fault Messages
7
–
Injection speed too low (Actual value for injection pressure < Set value) ––> Increase injection speed (see screen page ’20 PROCESS OPTIMIZATION’.
*>
Monitoring is actuated: Change over point was not reached within the given monitoring time (PN–Time) and\or within the selected monitoring pressure (PN_spec/hyd, PN Wid1, PN Wid2). Increase monitoring time and\or monitoring pressure, and\or increase enabling of holding pessure (enabling time should equate approx. to 0.8 x injection time).
–
Change over via time is switched on, but the selected position for monitoring of the injection process (PN–Volume/Stroke) has not been reached within this Time and\or monitoring pressure (PN_spec/hyd, PN Wid1, PN Wid2) has been reached or exceeded during this Time.
*>
Cavities full or overfilled:
–
Shot volume too great and\or change over to holding pressure too late (injection time too long).
*>
Cavities not completely full:
–
Melt temperature too low ––> increase cylinder temperatures (see screen page ’30 TEMPERATURES’).
–
Injection pressure too low (Actual value >= Set value) ––> increase Set value (see screen page ’20 PROCESS OPTIMIZATION’).
–
Injection speed too low (condition Actual value for injection pressure < Set value, ––> increase Set value, see screen page ’20 PROCESS OPTIMIZATION’.
*>
Monitoring is actuated: Selection for monitoring of stroke\volume has been made too low ––> increase PN Volume/Stroke, or selection of pressure monitoring has been made too low ––> increase PN_spec/hyd or PN– WID1/2, see screen page ’20 PROCESS OPTIMIZATION’ and\or increase holding pressure enabling time (enabling time should equate to approx. 0.8 x injection time).
–
BA027.01.1.en
Change over via a pressure (PN_spec/hyd, PN–WID1/2) is switched on. This pressure level has not been reached within monitoring time PN–Time and\or reached prior to dropping below the given stroke point.
7-13
7
Fault Elimination, Fault Messages
*>
Cavities full or overfilled:
–
Shot volume too great and\or change over to holding pressure too late – (Set value for change over pressure too high) – or enabling time for holding pressure too long (enabling time should equate to approx. 0.8 x injection time).
*>
Cavities not completely full:
–
Melt temperature too low ––> increase cylinder temperatures, see screen page ’30 TEMPERATURES’.
–
Injection pressure too low (Actual value >= Set value) ––> increase Set value (see screen page ’20 PROCESS OPTIMIZATION’).
–
Injection speed too low (condition – Actual value for injection pressure < Set value) ––> increase, (see screen page ’20 PROCESS OPTIMIZATION’).
–
Enabling time for holding pressure too short ––> set enabling time to approx. 0.8 to 0.9 x injection time (Actual value), see screen page ’20 PROCESS OPTIMIZATION’.
*>
Monitoring is actuated: Change over volume has been set too low (PN–Volume) ––> increase, or monitoring time has been set too short (PN–Time) ––> increase, see screen page ’20 PROCESS OPTIMIZATION’.
Nozzle guard not closed The nozzle guard on the injection unit is not closed properly. *>
Open and close the nozzle guard so that it engages correctly.
*>
Check safety switch –3S3.
*>
If the fault cannot be removed, call your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
Nozzle guard open – rear side The rear nozzle guard is not properly closed.
7-14
*>
Open and close the nozzle guard so that it engages properly.
*>
Check the safety switch.
*>
If the fault cannot be removed, contact your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
BA027.01.1.en
Fault Elimination, Fault Messages
7
Nozzle retraction not achieved The injection unit has not reached the pre–set position. *>
Please check for any mechanical obstruction and, if found, remove or alter ’Ejector forward’ position on screen page ’23 INJECTION UNIT’.
Oil filter blocked 100% *>
Replace dirty oil filter, see chap. 6 ’Maintenance’ in the operating manual.
Oil filter blocked 75% *>
Order new oil filter and on receipt replace, see chap. 6 ’Maintenance’ in the operating manual.
Oil level too low *>
Check oil level, top up hydr. oil if necessary, see chap. 5 ’Setting Up’ in the operating manual.
*>
Check connection between level switch and control system.
Oil pre–warming or switch ON program active *>
Switch off program switch ”Oil pre–warming” on screen page ’30 TEMPERATURES’ or program switch ”Switch on program” on screen page ’41 SWITCH–ON PROGRAM’.
Oil temperature too high Cooling water supply interrupted or water pressure too low. *>
Switch on cooling equipment and water supply.
*>
Use a larger pipe–or hose diameter for feed\discharge.
*>
Use shorter supply pipes.
*>
When was the oil cooler last serviced ? See chap. 5 ’Setting Up’ in the operating manual.
Oil temperature too low The oil temperature is too low for the selected function.Please carry out pre–heating of oil.See also screen page ’30 TEMPERATURES’.
BA027.01.1.en
7-15
7
Fault Elimination, Fault Messages
Optimising cylinder heating Cycle start not possible. *>
Observe Actual temperatures on screen page ’30 TEMPERATURES’. Cycle start is only possible when the
Check the wiring on the pump’s electronic system, on the pressure transducer and on the valve on the pump.
Pump not running Pump has not been switched on or switched off via monitoring– or switch–off program. To save emergy and reduce wear on the pump, it will also be switched off automatically after about 10 min. if no hydraulic functions have been carried out during this time. *>
Before restarting the cycle check the cause for switch–off using screen page ’2 ALARM DISPLAY’.
Program input missing You have programmed inputs to external signals. One of these signals is missing for the continuation of the cycle. *>
Check cause.
Quality flap fault The tilting mechanism on the QA–flap will not move. *>
Please ensure there is sufficient play.
Rear safety guard not closed The rear safety guards are not properly closed.
BA027.01.1.en
*>
Open and close them so that they engage properly.
*>
If this does not solve the problem, call your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
7-17
7
Fault Elimination, Fault Messages
Reject monitor not tripped Reject monitoring has indicated either no component ejection or incomplete ejection. Before the next cycle begins the signal from the monitoring unit must indicate that it is actuated and then enabled, or enabled and then reactuated. Remove cold slug or intrusion interrupted The maximum value for screw stroke/shot volume has been exceeded. *>
Gradually increase back pressure so that the setting for shot volume is almost reached but not exceeded.
Robot error (see page 73) *>
Select screen page ’73 ROBOT–GENERAL DATA’ to establish the cause of the problem. For further information refer to the robot operating manual.
Robot Off line Data exchange between the Ergocontrol and the robot control system is faulty; an off–line message is given on each robot screen page ’70...–76.. and 79’. *>
Re–load robot program with robot boot disc.
*>
Re–load Ergocontrol with Ergocontrol boot disc. If after this the problem still exists, contact your Demag Ergotech Service Department.
Rotation transducer defective *>
Check sensor on wire break and function and, if necessary, change sensor.
*>
Check the distance from sensor to impulse disc.
Safety bar –2S114 not made or defective Monitoring of the safety bar function has been actuated. *>
7-18
Check the cause; if you suspect that the switch function has failed, contact your Demag Ergotech Service Department.
BA027.01.1.en
Fault Elimination, Fault Messages
7
Safety equipment should only be repaired by Demag Ergotech Service Technicians. Safety bar –2S115 not made or defective Monitoring of the safety bar function has been actuated. *>
Check the cause; if you suspect that the switch function has failed, contact your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
Safety bar –2S114 made not released Monitoring of the safety bar function has been actuated. *>
Check the cause; if you suspect that the switch function has failed, contact your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
Safety door end switch problem –2S1,–2S2 Open and close guard doors; if this does not eliminate the problem –
telephone your Demag Ergotech Service Department. Safety equipment should only be repaired by Demag Ergotech Service Technicians.
Screw back not reached The screw has not reached the set position. *>
BA027.01.1.en
Complete metering in manual mode and retract the screw; then change back to semi– or fully automatic operation.
7-19
7
Fault Elimination, Fault Messages
Set–up control or dry cycle active You have switched on specific programs on screen page ’96 COMMISSIONING’. *>
Check that these set–up–, calibration– or optimisation processes have finished and then reset the relevant switches on this screen. Warning: Optimisation of heating is active if the
Please check whether the ”Arm out” valve is set
*>
Please check compressed air supply and arm locking
Sprue picker not fully out The sprue picker moves out, but the signal ”Arm is out” is not reached within 2 secs. *>
Please check arm position and initiators
Start–up program active You have initiated the start–up program (screen page ’42 STARTUP PROGRAM’). In line with your programming, the given number of shots are processed as per settings for ”Step 1” or ”Step 2”, before continuing to operate on the setting for ”Normal operation”. *>
7-20
Set ”Reset start–up program” switch before restarting the program.
BA027.01.1.en
Fault Elimination, Fault Messages
7
Stroke measurement problem Check the stroke measurement system via screen page ’96 COMMISSIONING’. *>
If it is a calibration error then re–calibrate the stroke measurement system, see the operating manual for screen page ’96 COMMISSIONING’
*>
If this does not remove the fault, change the stroke measurement system and calibrate it, or check the wiring.
SVH not closed/opened The nozzle seal has not reachod its respective end point, or position switch –4B25 (–4B26) is faulty. *>
Check cause. If faults are suspected on the switch functions, contact Demag Ergotech Service.
Switch OFF program active This program has either been activated manually via screen page ’49 OFF–ON–PROGRAM’ or automatically via screen page ’43 PURGING PROGRAM’. Temperature controller problem *>
An external temperature control unit registers a fault; look for the cause on the temperature control unit.
Temperature deviation Set temperatures for every zone must be reached prior to cycle start. *>
If a +tolerance is exceeded i.e. constant heating when operating factor ED=0%, check relevant Triac–switch 6–V....
*>
If a temperature falls below a –tolerance and operating factor ED=99%, check the relevant Triac–switch 6–V.... and the fuse. Note: Heating monitoring active The error message can only be reset after all the heating zones have cooled down and are within the positive tolerance band again or have heated up and are within the negaitive tolerance band again, by switching off and then resetting the program switch ”Heating monitoring”.
BA027.01.1.en
7-21
7
Fault Elimination, Fault Messages
Temperature deviation mould heating Set temperatures for all zones must be reached before the cycle starts. *>
If a +tolerance is exceeded i.e. constant heating (Actual temperature rises continuously), check the relevant relay.
*>
If a temperature falls below a –tolerance and the Actual temperature is dropping, check the relevant relay or the fuse. Note: Heating monitoring active The error message can only be reset after all the heating zones have cooled down and are within the positive tolerance band again or have heated up and are within the negaitive tolerance band again, by switching off and then resetting the program switch ”Heating monitoring”.
Temperature deviation hot runner Set temperatures for all zones must be reached before the cycle starts. *>
If a +tolerance is exceeded i.e. constant heating when the operating factor (ED)=0%, check the relevant Triac switch 6–V....
*>
If a temperature falls below a –tolerance when the operating factor (ED)=99%, check the relevant Triac switch 6–V.... or the relevant fuse. Note: Heating monitoring active The error message can only be reset after all the heating zones have cooled down and are within the positive tolerance band again or have heated up and are within the negaitive tolerance band again, by switching off and then resetting the program switch ”Heating monitoring”.
Temperature reduction active The machine regulates all heating zones to reach the set reductions in temperature. To restart the cycle, reset program switch ”Temperature reduction” or set temperature value to ”0” (screen page ’30 TEMPERATURES’ and ’31 HOT RUNNER1–16’) andwait for Set temperatures to be reached.
7-22
BA027.01.1.en
Fault Elimination, Fault Messages
7
Tolerance deviation The limit for the frequency of tolerance deviation for one parameter has been reached, see screen page ’52 CONT. PROCESS CONTROL’. The machine has stopped. Wrong boot disc Only use boot diskettes with the correct machine no.!
BA027.01.1.en
7-23
Table of contents
8
8
Function Number Index 8.1
Function Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8.2
Function Numbers – Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
8.2.1
Function Numbers – Hydraulics – Functions Group 1 . . . . . . . . . . . . . . . . . . .
8-2
8.2.2
Function Numbers – Hydraulics – Functions Group 2 . . . . . . . . . . . . . . . . . . .
8-4
8.2.3 8.2.3.1
Function Numbers – Hydraulics – Functions Group 3 . . . . . . . . . . . . . . . . . . . Function Numbers – Hydraulics Ergotech 125/475 up to 350/810 and 420/810 . . . . . . . . . . . . . . . . . . . . . . . . . . . Function Numbers – Hydraulics Ergotech 420/800 and 500/900 up to 2000/1800 . . . . . . . . . . . . . . . . . . . . . . . . .
8-6 8-6
8.2.4
Function Numbers – Hydraulics – Functions Group 4 . . . . . . . . . . . . . . . . . .
8-7
8.3
Function Numbers – Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9
8.3.1
Function Numbers – Electrical – Functions Group 1 . . . . . . . . . . . . . . . . . . . .
8-9
8.3.2
Function Numbers – Electrical – Functions Group 2 . . . . . . . . . . . . . . . . . . . .
8-12
8.3.3
Function Numbers – Electrical – Functions Group 3 . . . . . . . . . . . . . . . . . . . .
8-17
8.3.4
Function Numbers – Electrical – Functions Group 4 . . . . . . . . . . . . . . . . . . . .
8-18
8.3.5
Function Numbers – Electrical – Functions Group 6 . . . . . . . . . . . . . . . . . . . .
8-20
8.2.3.2
BA027.01.1.en
8-6
I
Function Number Index
8
8
Function Number Index All electrical units fitted on the machine are identified by a function number as per DIN 40719 Part 2. Note: Before changing or installing a unit, we strongly recommend labelling the new one to correspond with the old.
8.1
Function Groups The machine is divided up into the following Function Groups to give a better overview of the operating sequence. 1
– Energy Supply and Control System
2
– Clamping Unit SE
3
– Injection Unit IU
4
– Screw Drive
5
– Free
6
– Screw Cylinder Heating
Example: Solenoid –2Y3 to directional control valve 2SH3
–2Y3 Function Group
Counter
Solenoid
BA027.01.1.en
8-1
8
Function Number Index
8.2
Function Numbers – Hydraulics
8.2.1
Function Numbers – Hydraulics – Functions Group 1 1DB1 1DB1.1 1DB2
Pressure relief valve for high pressure Pressure relief valve for hydraulic pressure Pressure relief valve for high pressure pump 1PV2 (Ergotech 125/475 up to 350/810 and 420/810 system)
1DM1.1
Pressure reduction valve for control–oil (Ergotech 125/475 up to 350/810 and 420/810 system and Ergotech 420/800 up to 74kW)
1FT1(.3) 1FT5(.1–.3)
Oil suction filter High pressure oil filter
1FV5
Priming valve for pump 1PV2 (Ergotech 125/475 up to 350/810 and 420/810 system)
1MA1
Main manometer
1PV1(.1–.3) 1PV2
Variable pump 1(.1–.3) Variable pump 2 (Ergotech 125/475 up to 350/810 and 420/810 system) Constant pump (Ergotech off 37 kW)
1PF2(.1–.3) 1RV1
Non–return valve for pump 1PV1 Ergotech 125/475 bis 350/810 and 420/810 concept: 1PV1 (1PF2) Ergotech 420/800 and from 500/900: 1PF2(.1) 1RV2 Non–return valve on pipe pump – 1PV1 (Ergotech concept up to 30 kW) – 1PV2 (Ergotech system) 1RV6 Non–return valve on pipe pump – 1PV1 (Ergotech concept up to 30 kW) – 1PV2 (Ergotech 125/475 up to 350/810 and 420/810 system) 1RV11 Non–return valve on priming pipe pressure 1RV26.1(.2–.4) Non–return valves on overflow–oil pipe pump 1PV1 (up to IU 8000) 1RV27(.1–.3) Non–return valve for suction pump 1PV1 1RV28(.2–.3) Non–return valve for pump 1PF1.2 (off 74 kW)
8-2
BA027.01.1.en
Function Number Index
8
Function Numbers – Hydraulics – Functions Group 1 – Continued 1SH1
1SH7(.1–.3) 1SH11 1SH20(.2–.3) 1SH23
BA027.01.1.en
Proportional directional control valve for volume 1PV2(.2–.3) (Ergotech 125/475 up to 350/810 and 420/810 system) Proportional directional control valve for volume 1PV1 Directional control valve for arallel functions (Ergotech system) Directional control valve for pressure rise of pump 1PF1.2 (off 74 kW) Directional control valve for switching on oil preheating
1SV8
Cartridge valve for parallel functions (Ergotech 125/475 up to 350/810 and 420/810 system)
1WT1
Hydraulic oil cooler
8-3
8
8.2.2
Function Number Index
Function Numbers – Hydraulics – Functions Group 2 2DB1 2DB22
Pressure relief valve for tie bar protection Proportional pressure adjusting valve for mould safety (by Ergotech 420/800 and from 500/900 up to 2000/1800)
2DE15
Proportional pressure adjusting valve for cores (only by proportional = ZE) Throttle–non–return valve oil–volume core 1 (not by proportional=ZE) (by Ergotech 420/800 and from 500/900 up to 2000/1800) Throttle–non–return valve oil–volume core 2 (not by proportional=ZE) Throttle–non–return valve oil–volume core 3 (not by proportional = ZE) Throttle–non–return valve oil–volume core 4 (not by proportional = ZE) Throttle–non–return valve oil–volume core 5 (not by proportional = ZE) Throttle–non–return valve oil–volume core 6 (not by proportional = ZE)
2DR13/14
2DR15/16 2DR17/18 2DR19/20 2DR53/54 2DR55/56
2KV16
Pressure reduction valve for cores (only by prop.=ZE)
2MA13
Manometer for cores (only by prop. = ZE)
2RV2 2RV3
Non–return valve for directional control valve 2SH4 Non–return valve for directional control valve 2SH4 (up to 74 kW)
2RV4
Non–return valve for control of mould clamping pressure (by Ergotech concept=WA) Non–return valve with electronic monitoring for mould safety Non–return valve for pressure relief (by Ergotech concept=WA) Non–return valve on pressure pipe hydr. ejector Non–return valve on priming pipe for cores Electrically controlled non–return valve for core 1 Electrically controlled non–return valve for core 2 Electrically controlled non–return valve for core 3 Electrically controlled non–return valve for core 4 Non–return valve on priming pipe hydraulic ejector Non–return valve on priming pipe clamping unit Electrically controlled non–return valve for core 5 Electrically controlled non–return valve for core 6
2RV5 2RV12 2RV16 2RV19 2RV43 2RV44 2RV48 2RV49 2RV60 2RV76.1(.2) 2RV81 2RV82
8-4
BA027.01.1.en
Function Number Index
8
Function Numbers – Hydraulics – Functions Group 2 – Continued 2RV92 2RV96/97 2RV98/99 2RV100/101 2RV102/103 2RV152/153 2RV154/155
Non–return valve for differential switches Non–return valve for pressure relief core 1 Non–return valve for pressure relief core 2 Non–return valve for pressure relief core 3 Non–return valve for pressure relief core 4 Non–return valve for pressure relief core 5 Non–return valve for pressure relief core 6
2SH1
Proportional directional control valve for mould closing and opening. Directional control valve for differential switching (by Ergotech concept=WA) Directional control valve with electrical monitoring of mould safety. Proportional directional control valve for hydraulic ejector (Ergotech 125/475 up to 350/810 and 420/810 proportional=ZE, Ergotech 420/800 and from 500/900 proportional) Directional control valve for core 1 (proportional = ZE) Directional control valve for core 2 (proportional = ZE) Directional control valve for core 3 (proportional = ZE) Directional control valve for core 4 (proportional = ZE) Directional control valve for core 5 (proportional = ZE) Directional control valve for core 6 (proportional = ZE) Directional control valve for pressure relief cores manuell
2SH3 2SH4 2SH5
2SH13 2SH15 2SH17 2SH19 2SH108 2SH109 2SH129
BA027.01.1.en
2SV3 2SV4
Cartridge valve on tank supply line – mould open Cartridge valve for start of differential switching (by Ergotech concept=WA)
2WV8
Shuttle valve for ejection pressure (only by prop.)
2ZY1 (.1–2) 2ZY6
Clamping cylinder Ejection cylinder
8-5
8
8.2.3 8.2.3.1
8.2.3.2
8-6
Function Number Index
Function Numbers – Hydraulics – Functions Group 3 Function Numbers – Hydraulics Ergotech 125/475 up to 350/810 and 420/810 3MA1
Manometer for nozzle sealing
3RV3 3RV8 3RV12
Non–return valves on pressure pipe movement cylinder (only by Ergotech concept) Non–return valve for nozzle sealing residual pressure Non–return valve on delivery pipe movement cylinder
3SH1 3SH3
Directional control valve for nozzle forward and back Directional control valve for nozzle sealing pressure
3ZY1.1 3ZY1.2
Movement cylinder Movement cylinder
Function Numbers – Hydraulics Ergotech 420/800 and 500/900 up to 2000/1800 3RV3
Non–return valves on pressure pipe movement cylinder
3SH1
Directional control valve for nozzle forward and back
3ZY1.1 3ZY1.2
Movement cylinder Movement cylinder
BA027.01.1.en
Function Number Index
8.2.4
8
Function Numbers – Hydraulics – Functions Group 4 4AS3 4AS4 4DB1
Accumulator safety valve (only by Ergotech with accumulator=ZE)
4DE11
Pressure adjusting valve for screw back pressure (only by Ergotech concept and Ergotech 420/900 and from 500/900 with DFE regulated)
4DM5 4DM8
Pressure relief valve for hydraulic shut–off nozzle Pressure relief valve for control of hot runner feed system Oil pressure switch for charge accumulator (only by Ergotech with accumulator=ZE)
4DS1 4MA1
4MA7
Manometer for accumulator pressure (only by Ergotech with accumulator=ZE) Manometer for screw back pressure (only by Ergotech concept 420/800 and from 500/900 with DFE regulated) Manometer for hydraulic shut–off nozzle Manometer for injection–, follow–up, screw back pressure (not DFE regulated = ZE ) only Ergotech 420/800 and 500/900 up to 2000/1800 Manometer for control of hot runner feed system
4MF1
Hydraulic motor for screw drive
4RV2 4RV10
Non–return valve for suction by metering Non–return valve in control pipe injection (only by Ergotech with accumulator=ZE) Non–return valve in control pipe injection (only by Ergotech with accumulator=ZE) Non–return valve on pressure pipe injection (only by Ergotech with accumulator=ZE) Non–return valve on pressure for hydraulic shut–off nozzle Non–return valve for pressure pipe for control of hot runner feed system Non–return valve for priming pipe for directional control valve 4SH1 Non–return valve for priming pipe for directional control valve 4SH1
4MA3
4MA5 4MA6
4RV11 4RV12 4RV16 4RV70 4RV71 4RV81
BA027.01.1.en
Shut–off valve for pressure indication of accumulator pressure (only by Ergotech with accumulator=ZE) Shut–off valve for manual discharge of accumulator (only by Ergotech with accumulator=ZE)
8-7
8
Function Number Index
Function Numbers – Hydraulics – Functions Group 4 – Continued 4SH1 4SH4 4SH5 4SH8 4SH10 4SH40
4SP1(.1–.4)
Pressure accumulator for fast injection (only by Ergotech with accumulator=ZE)
4SV3
Cartridge valve for screw back pressure (only by Ergotech concept and Ergotech 420/800 and from 500/900 with DFE regulated) Cartridge valve for metering Cartridge valve for injection with accumulator (only by Ergotech with accumulator=ZE)
4SV4 4SV10
8-8
Directional control valve for injection and screw retraction (only by Ergotech system proportional=ZE) Directional control valve for metering Directional control valve for hydraulic shut–off nozzle Directional control valve for autom. discharging of accumulator (only by Ergotech with accumulator=ZE) Directional control valve for injection with accumulator (only by Ergotech with accumulator=ZE) Directional control valve for control of hot runner feed system
4WV10
Shuttle valve for pressure transducer in injection cylinder (only by Ergotech system with electr. screw drive)
4ZY1(.1–.2) 4ZY5
Injection cylinder Cylinder for hydraulic shut–off nozzle
BA027.01.1.en
Function Number Index
8.3
Function Numbers – Electrical
8.3.1
Function Numbers – Electrical – Functions Group 1 –K1 –K2 –K3 –K4 –K5 –K6
BA027.01.1.en
8
Relay for 1. free programmable output Relay for 2. free programmable output Relay for 3. free programmable output Relay for 4. free programmable output Relay for 5. free programmable output Relay for 6. free programmable output
–1A4 –1A 5 –1A 14 –1A 14(.05–.24) –1A 20 –1A 28(.00–.03) –1A70(.1 –.3) –1A112 –1A114
Ergolink unit Intelligent operator terminal SPS–Controls (CPU) – general I/O unit for SPS control Socket combination Expansion unit for SPS controls Control system for pump Mains/plug transformer for Ergolink Base I/O for SPS control
–1B1 –1B2.1(.2 –.3) –1B3 –1B6(.1–.3) –1B21 –1B23 –1B24
Thermocouple for hydraulic oil Switch – contaminated oil filter Level switch – monitoring of hydraulic oil level Transducer for hydraulic pressure Transducer for proportional valve –1Y21 Transducer for energy consumption measurement Transducer for energy consumption measurement
–1F2(.1–.2) –1F8 –1F9(.1–.6) –1F12 –1F13(.1 –.3) –1F14(.1–.2) –1F15 –1F16
Overload relay for pump motor Automatic circuit–breaker for failure monitoring interface Automatic circuit breaker 24 V = Automatic circuit breaker socket –1X112 Automatic circuit breaker control system 24 V – AC Automatic circuit breaker 24 V dc for solenoids Automatic circuit breaker socket –1X15 Automatic circuit breaker socket –1X16
–1F17 –1F18 –1F21 –1F35 –1F40 –1F115 –1F117
Automatic circuit breaker socket –1X17 Automatic circuit breaker socket –1X18 Current limiter for motor protection switch Pre–fuse for socket combination Automatic circuit breaker for control voltage ON/OFF Fault current switch for –1F15/–1F16 Fault current switch for–1F17/–1F18
8-9
8
Function Number Index
Function Numbers – Electrical – Functions Group 1 – Continued –1G1
Power unit 1 24 V dc for solenoids
–1H10 –1H31 –1H35 –1H46
Signal light for position ”O” of safety switch ”SUVA” Signal light for control voltage ON/OFF General fault indication – optical General fault indication – audible
–1K1(.1–.2) –1K2(.1–.2) –1K3(.1–.2) –1K5(.2–.3) –1K8 –1K9 –1K10 –1K11 –1K12 –1K21 –1K40 –1K41(.1–.2) –1K50 –1K59
Power supply protection – pump drive motor Star protection – pump drive motor Delta protection – pump drive motor Relais α SOLL 2./.3 pump = 0 Protection for socket combination Switch off protection for socket combination Relay for cycle control Relay for optical fault indication Relay for audible fault indication Relay for pump motor ”ON” Relay for control voltage ON/OFF Relay for Emergency – Stop Safety relay for foot operated safty platform Relay for pre–heating of hydraulic oil
–1M1(.1–.3)
Pump drive motor
–1Q0 –1Q1(.1–.2) –1Q4.1(.2) –1Q8
Main switch Circuit breaker for pump motor Star–Delta switch for pump motor Safety switch for control cabinet
–1R2 –1R21
Plug with resistor for CAN – BUS Varistor for relay –1K21
–1S6.1(.2) –1S10 –1S31 –1S38 –1S40
Limit switch for foot operated safty platform Safety switch ”SUVA” ON–OFF switch for pump motor Start button on Ergocontrol Switch for control voltage ON/OFF
–1S42 –1S42.1 –1S42.2
Switch for Emergency–Stop Switch for Emergency–Stop (non–operator side) Switch for Emergency–Stop (mould internal area operator side) Switch for Emergency–Stop (mould internal area non–operator side)
–1S42.3
8-10
BA027.01.1.en
Function Number Index
8
Function Numbers – Electrical – Functions Group 1 – Continued –1T3 –1T8(.1–.2)
–1T40
24 V Transformer Current transformer for energy consumption measurement Current transformer for energy consumption measurement Current transformer for energy consumption measurement Transformer for control voltage ON/OFF
–1U1
Optocoupler for EMERGENCY STOP
–1V1
Rectifier for 24 V DC/2A
–1X1 –1X2 –1X3 –1X7 –1X10 –1X11 –1X12 –1X13(.1–.2) –1X14.1(.2) –1X15 –1X16 –1X17 –1X18 –1X40 –1X112(.1) –1X114
Socket for RS 232 (free) Socket for RS 232 (free) Socket for RS 232 (free) Socket for CAN – BUS Socket for ” ARCNET ” CIM computer Socket for connection control panel –1A1 Socket for external printer Connection for integral printer –1Y99 in control panel –1A1 Socket for diagnose plug Schuko socket combinations – 2 pol. + PE (in –1A20) Schuko socket combinations – 2 pol. + PE (in –1A20) Cchap. form socket combinations CEE form socket combinations Connection for control voltage ON/OFF 220 V Service socket Interface for DIAS–BUS
–1Y11 –1Y20.2(.3) –1Y23 –1Y24 –1Y99
Solenoid for parallel functions Solenoid for addit. pressure reduction Solenoid for preheating of hydraulic oil Solenoid for oil cooling Integral printer in Ergocontrol
–1Z3 –1Z4 –1Z5 –1Z10 (.1–.2) –1Z20 (.1–.2) –1Z30 (.1–.2) –1Z40
Ferrite core for + 24V DC (–1G1) Ferrite core for + 24V DC (–1G1) Ferrite core for printer –1Y99 RC–element for power supply protection –1K1 RC–element for star protection –1K2 RC–element for delta protection –1K3 RRC–element for relay –1K40
–1T9 –1T10
BA027.01.1.en
8-11
8
8.3.2
Function Number Index
Function Numbers – Electrical – Functions Group 2 –2A1 –2A2 –2A3 –2A4 –2A8 –2A11 –2A12 –2A13(.1) –2A62 –2A86 –2A113 –2A115 –2A117 –2A119 –2A121 –2A123
Temperature control unit 1 Temperature control unit 2 Temperature control unit 3 Temperature control unit 4 Robot for handling Control valve for hydraulic ejector Control valve for Mould Open/Closed Lubrication unit for clamping unit Control valve for pressure adjusting cores Control valve for pressure adjusting Mould Safety Control valve for pressure adjusting core 1 Control valve for pressure adjusting core 2 Control valve for pressure adjusting core 3 Control valve for pressure adjusting core 4 Control valve for pressure adjusting core 5 Control valve for pressure adjusting core 6
–2B3 –2B14 –2B15 –2B18 –2B39 –2B54 –2B55 –2B62 –2B66 –2B86
Clamping force transducer Limit switch – hydraulic ejector forward stop Limit switch – hydraulic ejector back stop Pressure transducer for hydraulic ejector Transducer for guard door operator side open Thermocouple for mould– Circuit 1 Thermocouple for mould– Circuit 2 Transducer for proportional valve –2Y62 Pneumatic rails on auto. guard door Transducer for proportional valve 2DB22 – Mould Safety Limit switch – mould safety – ejector plate Transducer for Slides safety mechanism Timer for clamp force adjustment Level switch – oil lubrication Pressure switch – monitoring of oil lubrication Transducer for mechanical locking pawl operator side Transducer for locking pawl operator side
–2B87 –2B89 –2B220 –2B222 –2B225 –2B237 –2B238
8-12
BA027.01.1.en
Function Number Index
8
Function Numbers – Electrical – Functions Group 2 – Continued –2K9(.1–.2) –2K13 –2K17(.1–.4) –2K19 –2K20 –2K32 –2K33 –2K45 –2K46(.1 –2K50 –2K919 –2M3 –2M10
Variable displacement motor for mould mounting height Motor for oil lubrication pump on clamping unit
–2N6
Clamping force controller
–2P3
Photo–electric detector for component weighing system
–2Q1
Motor safety switch for variable displacement motor –2M3 Circuit breaker for integrated temperature control units
–2Q2 –2R2 –2R5 –2R23 –2R24 –2R46 –2R54
Stroke measuring system for mould stroke Resistor for clamping force control Stroke measuring system for hydraulic ejector Stroke measuring system for mould mounting height Varistor for relay –2K46 NTC resistor for temp. compensation –1A14.18
–2S1 –2S1.1 –2S1.2 –2S2 –2S2.1 –2S2.2 –2S3 –2S4 –2S6.1
Limit switch – guard door on operator side Limit switch – guard door on mould carriage Limit switch – guard door on non–operator side Limit switch – guard door on operator side Limit switch – guard door on mould carriage Limit switch – guard door on non–operator side Limit switch for mould safety mechanism Switch for NO MOTION / MOTION (nur USA) Limit switch for foot operated safty platform (from Ergotech 1000) Limit switch for foot operated safty platform (from Ergotech 1000)
–2S6.2
BA027.01.1.en
Relay switch–off of temperature control units in the event of a fault Relay for oil lubrication pump Relay for protection of mould space Relay for Safety gate close (BS) Relay for Safety gate close (BSG) Relay for release of ejection monitoring Relay for stepped conveyor Relay for mould height adjustment Relay for mould height adjustment Relay for mould mounting height Relay for EMERGENCY STOP actuated from Handling
8-13
8
Function Number Index
Function Numbers – Electrical – Functions Group 2 – Continued –2S10 –2S11 –2S12 –2S13 –2S22 –2S23 –2S24 –2S25 –2S26 –2S27 –2S28 –2S29 –2S70 –2S71 –2S72 –2S73 –2S101 –2S114 –2S216 –2S217 –2U1 –2U3
Optocoupler for input for guard door non–operator side closed Frequency convertor for variable displacement motor –2M3
–2V3.1(.2)
Triac for variable displacement motor
–2X1 –2X2 –2X3 –2X4 –2X5 –2X9 –2X10 –2X12
Connection for robot interface –2A8 Connection for temperature control unit 1, –2A1 Connection for temperature control unit 2, –2A2 Connection for temperature control unit 3, –2A3 Connection for temperature control unit 4, –2A4 Connection for prop. – valve –2Y5 / 6 Connection for solenoid –2Y1 Connection for limit switch 1...2 cores, –2S22...–2S25 Connection for limit switch 2...4 cores, –2S26...–2S29 Connection for pressure transducer – hydr. ejector –2B18 Connection for Temperature control unit Connection for Interface –Slides safety mechanism
–2X13 –2X18 –2X20 –2X26
8-14
Limit switch for sprue picker up Limit switch for sprue picker down Limit switch for mould release stroke terminated Limit switch for sprue gripped Limit switch – core 1 moved out Limit switch – core 1 moved in Limit switch – core 2 moved out Limit switch – core 2 moved in Limit switch – core 3 moved out Limit switch – core 3 moved in Limit switch – core 4 moved out Limit switch – core 4 moved in Limit switch – core 5 moved out Limit switch – core 5 moved in Limit switch – core 6 moved out Limit switch – core 6 moved in Limit switch monitoring on 2RV5 Limit switch – mould safety mechanism – mechanical limitation Limit switch – limiting of max. mould mounting height Limit switch – limiting of min. mould mounting height
BA027.01.1.en
Function Number Index
8
Function Numbers – Electrical – Functions Group 2 – Continued –2X30 –2X31 –2X32 –2X51 –2X60 –2X67 –2X68 –2X88 –2X101 –2X102 –2X103 –2X105 –2X113 –2X120 –2X126
BA027.01.1.en
Connection for limit switch 5...6 cores, –2S70... –2S73 Connection for temperature indication mould – circuit 1 Connection for temperature indication mould – circuit 2 Connection for ejector in mould, limit switch –2B14 / –2B15 Connection for closing force detector –2N6 (DIAS board) Connection for ejector monitoring –2P3 Connection for closing force detector –2N6 (measuring point) Connection for mould safety – ejector plate –2B87 Dummy plug for robot interface –2X1 Dummy plug for temperature control units – interfaces –2X2...–2X5 Dummy plug for limit switch – mould safety – ejector plate – interface –2X88 ummy plug for limit switch –2B15 Connection for oil lubricant unit –2A13 Connection for limit switch cores –2X12 / –2X3
–2X130.1 (.2)
Dummy plug for Slides safety mechanism – interfades –2X26 Dummy plug for temperature indication circuit 1(2)
–2Y3 –2Y5 / 6 –2Y11(.1–.2) –2Y12(.1–.2) –2Y13 –2Y14 –2Y15 –2Y16 –2Y17 –2Y18 –2Y19 –2Y20 –2Y22 –2Y24 –2Y26 –2Y27 –2Y28 –2Y32
Solenoid for differential switching Solenoid for hydraulic ejector forward/back Solenoid for air ejector (moving platen) Solenoid for air ejector (fixed platen) Solenoid for moving core 1 in Solenoid for moving core 1 out Solenoid for moving core 2 in Solenoid for moving core 2 out Solenoid for moving core 3 in Solenoid for moving core 3 out Solenoid for moving core 4 in Solenoid for moving core 4 out Solenoid for moulding cooling Solenoid for pressure protection for mould Solenoid for insert sprue picker Solenoid for retract sprue picker Solenoid for gripper closed and mould release stroke Solenoid for mould safety mechanism
8-15
8
Function Number Index
Function Numbers – Electrical – Functions Group 2 – Continued
8-16
–2Y37 –2Y38 –2Y39 –2Y70 –2Y71 –2Y72 –2Y73
Solenoid for guard door closing Solenoid for guard door opening Solenoid for guard door damping Solenoid for moving core 5 out Solenoid for moving core 5 in Solenoid for moving core 6 out Solenoid for moving core 6 in
–2Z5 –2Z6 –2Z13 –2Z14 –2Z15 –2Z16 –2Z17 –2Z18 –2Z19 –2Z20 –2Z37 –2Z38
Additional filter for Solenoid –2Y5 Additional filter for Solenoid –2Y6 Additional filter for Solenoid –2Y13 Additional filter for Solenoid –2Y14 Additional filter for Solenoid –2Y15 Additional filter for Solenoid –2Y16 Additional filter for Solenoid –2Y17 Additional filter for Solenoid –2Y18 Additional filter for Solenoid –2Y19 Additional filter for Solenoid –2Y20 Additional filter for Solenoid –2Y37 Additional filter for Solenoid –2Y38
BA027.01.1.en
Function Number Index
8.3.3
8
Function Numbers – Electrical – Functions Group 3
BA027.01.1.en
–3A1
Control valve for injection unit forward / back
–3B1
Pressure transducer–inject. unit forward – nozzle contact
–3K1(.1)
Safety relay for switch–off of dangerous movements on the injection unit
–3S3(.1–.2)
Limit switch – nozzle cover
–3X1
Connection for pressure switch –3B1
–3Y1 / 2 –3Y3
Solenoid for injection unit forward / back Solenoid fornozzle sealing force
8-17
8
8.3.4
Function Number Index
Function Numbers – Electrical – Functions Group 4 –4A1 –4A4 –4A11
Control valve for injection/screw retraction Kompat inverter/controller for el. SC motor –4M1 Regulating valve for back pressure
–4B3
–4B6 –4B9 –4B10 –4B16 –4B25 –4B26
Pressure transducer in injection cylinder (injection pressure) Pressure transducer in mould for change over to follow–up pressure dependent on injection pressure Thermocouple for feed zone Pressure switch – accumulator charged Transducer for servo valve –4Y1/2 Injection Transducer for screw speed Transducer for SVH closed Transducer for SVH open
–4K1 –4K25
Relay for el. screw–motor –4M1 Relay for pressure profile/discrimination package
–4Q1 –4Q2 –4Q26
Circuit breaker for screw–motor –4M1 Protection switch for ventilator for SC–motor –4M1 Automatic circuit breaker for material handling
–4R1 –4R2 –4R4
Stroke measuring system for nozzle stroke Stroke measuring system for screw Resistor for SC–motor –4M1
–4U3(.1–.2)
Amplifier for injection pressure dependent change over to follow–up pressure
–4V8 –4V61
Unloading diode for –4Y8 Unloading diode for –4Y61.1
–4X3
Connection for pressure transducer –4B3 in injection cylinder Connection for amplifier for change over to follow–up pressure dependent on injection pressure Connection for control valve –4A1 Connection for units –4B9, –4Y8 and –4Y10 Connection for speed transducer –4B16 Connection for speed transducer –4B16
–4B3.1(.2)
–4X3.1(.2) –4X4 –4X7 –4X16 –4X41
8-18
BA027.01.1.en
Function Number Index
8
Function Numbers – Electrical – Functions Group 4 – Continued
BA027.01.1.en
–4Y1 –4Y2 –4Y4 –4Y5 –4Y8 –4Y10 –4Y16 –4Y40 –4Y41 –4Y43 –4Y60 –4Y61.1 –4Y90
Solenoid for injection Solenoid for screw retraction Solenoid for metering Solenoid for SVH or hot runner nozzle Solenoid for automatic discharge of accumulator Solenoid for injection with accumulator Solenoid for SVH closing Solenoid for Solenoid for feed system Solenoid for screw back pressure Solenoid for Solenoid for nozzles closing Solenoid for cooling of feed zone Solenoid for enabling valve –4A1 Solenoid for leak oil discharge
–4Z1 –4Z5 –4Z10 –4Z16
Radio interferance filter for SC–motor –4M1 Additional filter for Solenoid –4Y5 Additional filter for Solenoid –4Y10 Additional filter for Solenoid –4Y16
8-19
8
8.3.5
Function Number Index
Function Numbers – Electrical – Functions Group 6 –6B1 –6B2 –6B3 –6B4 –6B5 –6B6 –6B10 –6B16 –6B35 –6B101 –6B102 –6B103 –6B104 –6B105 –6B106 –6B107 –6B108 –6B109 –6B110 –6B111 –6B112 –6B113 –6B114 –6B115 –6B116 –6B117 –6B118 –6B119 –6B120 –6B121 –6B122 –6B123 –6B124 –6B125 –6B126 –6B127 –6B128 –6B129 –6B130 –6B131 –6B132
8-20
Thermocouple MH 1 Thermocouple MH 2 Thermocouple MH 3 Thermocouple MH 4 Thermocouple MH 5 Thermocouple MH 6 Thermocouple DH Thermocouple for melt temperature Thermocouple DH 2 Thermocouple for hot runner – Zone HK 1 Thermocouple for hot runner – Zone HK 2 Thermocouple for hot runner – Zone HK 3 Thermocouple for hot runner – Zone HK 4 Thermocouple for hot runner – Zone HK 5 Thermocouple for hot runner – Zone HK 6 Thermocouple for hot runner – Zone HK 7 Thermocouple for hot runner – Zone HK 8 Thermocouple for hot runner – Zone HK 9 Thermocouple for hot runner – Zone HK 10 Thermocouple for hot runner – Zone HK 11 Thermocouple for hot runner – Zone HK 12 Thermocouple for hot runner – Zone HK 13 Thermocouple for hot runner – Zone HK 14 Thermocouple for hot runner – Zone HK 15 Thermocouple for hot runner – Zone HK 16 Thermocouple for hot runner – Zone HK 17 Thermocouple for hot runner – Zone HK 18 Thermocouple for hot runner – Zone HK 19 Thermocouple for hot runner – Zone HK 20 Thermocouple for hot runner – Zone HK 20 Thermocouple for hot runner – Zone HK 22 Thermocouple for hot runner – Zone HK 23 Thermocouple for hot runner – Zone HK 24 Thermocouple for hot runner – Zone HK 25 Thermocouple for hot runner – Zone HK 26 Thermocouple for hot runner – Zone HK 27 Thermocouple for hot runner – Zone HK 28 Thermocouple for hot runner – Zone HK 29 Thermocouple for hot runner – Zone HK 30 Thermocouple for hot runner – Zone HK 31 Thermocouple for hot runner – Zone HK 32
BA027.01.1.en
Function Number Index
8
Function Numbers – Electrical – Functions Group 6 – Continued –6F0(.1–.2) Automatic circuit breaker for screw cylinder heating –6F1(.1–.2) Automatic circuit breaker for heater band MH 1 –6F2(.1–.2–.3) Automatic circuit breaker for heater band MH 2 –6F3(.1–.2–.3) Automatic circuit breaker for heater band MH 3 –6F4(.1–.2) Automatic circuit breaker for heater band MH 4 –6F5(.2) Automatic circuit breaker for heater band MH 5 –6F6(.1–.2) Automatic circuit breaker for heater band MH 6 –6F10 Automatic circuit breaker for heater band DH –6F100(.1–.2) Automatic circuit breaker for mould heating/hot runner –6F101 Automatic circuit breaker for hot runner Zone HK 1 –6F102 Automatic circuit breaker for hot runner Zone HK 2 –6F103 Automatic circuit breaker for hot runner Zone HK 3 –6F104 Automatic circuit breaker for hot runner Zone HK 4 –6F105 Automatic circuit breaker for hot runner Zone HK 5 –6F106 Automatic circuit breaker for hot runner Zone HK 6 –6F107 Automatic circuit breaker for hot runner Zone HK 7 –6F108 Automatic circuit breaker for hot runner Zone HK 8 –6F109 Automatic circuit breaker for hot runner Zone HK 9 –6F110 Automatic circuit breaker for hot runner Zone HK 10 –6F111 Automatic circuit breaker for hot runner Zone HK 11 –6F112 Automatic circuit breaker for hot runner Zone HK 12 –6F113 Automatic circuit breaker for hot runner Zone HK 13 –6F114 Automatic circuit breaker for hot runner Zone HK 14 –6F115 Automatic circuit breaker for hot runner Zone HK 15 –6F116 Automatic circuit breaker for hot runner Zone HK 16 –6F117 Automatic circuit breaker for hot runner Zone HK 17 –6F118 Automatic circuit breaker for hot runner Zone HK 18 –6F119 Automatic circuit breaker for hot runner Zone HK 19 –6F120 Automatic circuit breaker for hot runner Zone HK 20 –6F121 Automatic circuit breaker for hot runner Zone HK 21 –6F122 Automatic circuit breaker for hot runner Zone HK 22 –6F123 Automatic circuit breaker for hot runner Zone HK 23 –6F124 Automatic circuit breaker for hot runner Zone HK 24 –6F125 Automatic circuit breaker for hot runner Zone HK 25 –6F126 Automatic circuit breaker for hot runner Zone HK 26 –6F127 Automatic circuit breaker for hot runner Zone HK 27 –6F128 Automatic circuit breaker for hot runner Zone HK 28 –6F129 Automatic circuit breaker for hot runner Zone HK 29 –6F130 Automatic circuit breaker for hot runner Zone HK 30 –6F131 Automatic circuit breaker for hot runner Zone HK 31 –6F132 Automatic circuit breaker for hot runner Zone HK 32
BA027.01.1.en
8-21
8
Function Number Index
Function Numbers – Electrical – Functions Group 6 – Continued –6K2 –6K3 –6K4 –6K5 –6K6 –6K21
8-22
–6K26(.1–.2) –6K27(.1–.2) –6K31 –6K33
Relay for fan motor –6M2 Relay for fan moto –6M3 Relay for fan moto –6M4 Relay for fan moto –6M5 Relay for fan moto –6M6 Relay for screw cylinder heating on, switch–on program Relay switch–off of mould heating Relay for switch–off of screw cylinder heating Relay for screw cylinder heating on Relay for moulding heating on
–6M2 –6M3 –6M4 –6M5 –6M6
Fan motor –6M2 for SC cyl. heating MH2 Fan motor –6M3 for SC cyl. heating MH3 Fan motorr –6M4 for SC cyl. heating MH4 Fan motorr –6M4 for SC cyl. heating MH5 Fan motorr –6M4 for SC cyl. heating MH6
–6Q1(.1–.2) –6Q2(.1–.2–.3) –6Q3(.1–.2–.3) –6Q4(.1–.2) –6Q10 –6Q17(.2–.6) –6Q20 –6Q21 –6Q22 –6Q23 –6Q24 –6Q25 –6Q26 –6Q27 –6Q28 –6Q29 –6Q30 –6Q31 –6Q35 –6Q43 –6Q44 –6Q45 –6Q46 –6Q98
Circuit breaker for heater band MH 1 Circuit breaker for heater band MH 2 Circuit breaker for heater band MH 3 Circuit breaker for heater band MH 4 Circuit breaker for heater band DH Motor protection switch for fan motor (–4M2 ...–4M6) Circuit breaker for hot runner Zone HK 1 Circuit breaker for hot runner Zone HK 2 Circuit breaker for hot runner Zone HK 3 Circuit breaker for hot runner Zone HK 4 Circuit breaker for hot runner Zone HK 5 Circuit breaker for hot runner Zone HK 6 Circuit breaker for hot runner Zone HK 7 Circuit breaker for hot runner Zone HK 8 Circuit breaker for hot runner Zone HK 9 Circuit breaker for hot runner Zone HK 10 Circuit breaker for hot runner Zone HK 11 Circuit breaker for hot runner Zone HK 12 Circuit breaker for heater band DH2 Circuit breaker for hot runner Zone HK 13 Circuit breaker for hot runner Zone HK 14 Circuit breaker for hot runner Zone HK 15 Circuit breaker for hot runner Zone HK 16 Main switch heating
BA027.01.1.en
Function Number Index
8
Function Numbers – Electrical – Functions Group 6 – Continued –6R26 –6R27 –6R40 –6R41 –6R42 –6R43 –6R44 –6R45
BA027.01.1.en
Varistor for relay –6K26 Varistor for relay –6K27 NTC resistor for temp. compensation SC cyl. heating NTC resistor for temp. compensation mould heating/ temp. unit NTC resistor for temp. compensation hotrunners HK 1...8 NTC resistor for temp. compensation hotrunners HK 9...16 NTC resistor for temp. compensation hotrunners HK 17...24 NTC resistor for temp. compensation hotrunners HK 25...32
–6S31 –6S33
Switch for screw cylinder heating on Switch for mould heating on
–6V1(.1–.22) –6V2(.1–.22) –6V3(.1–.23) –6V4(.1–.22) –6V5(.11–.22) –6V6(.11–.22) –6V10 –6V20 –6V21 –6V22 –6V23 –6V24 –6V25 –6V26 –6V27 –6V28 –6V29 –6V30 –6V31 –6V35 –6V43 –6V44 –6V45 –6V46 –6V50 –6V51
Triac for heating zone MH 1 Triac for heating zone MH 2 Triac for heating zone MH 3 Triac for heating zone MH 4 Triac for heating zone MH 5 Triac for heating zone MH 6 Triac for heating zone DH Triac for hot runner zone HK 1 Triac for hot runner zone HK 2 Triac for hot runner zone HK 3 Triac for hot runner zone HK 4 Triac for hot runner zone HK 5 Triac for hot runner zone HK 6 Triac for hot runner zone HK 7 Triac for hot runner zone HK 8 Triac for hot runner zone HK 9 Triac for hot runner zone HK 10 Triac for hot runner zone HK 11 Triac for hot runner zone HK 12 Triac for heating zone DH2 Triac for hot runner zone HK 13 Triac for hot runner zone HK 14 Triac for hot runner zone HK 15 Triac for hot runner zone HK 16 Triac for hot runner zone HK 17 Triac for hot runner zone HK 18
8-23
8
Function Number Index
Function Numbers – Electrical – Functions Group 6 – Continued –6V52 –6V53 –6V54 –6V55 –6V56 –6V57 –6V58 –6V59 –6V60 –6V61 –6V62 –6V63 –6V64 –6V65
Triac for hot runner zone HK 19 Triac for hot runner zone HK 20 Triac for hot runner zone HK 21 Triac for hot runner zone HK 22 Triac for hot runner zone HK 23 Triac for hot runner zone HK 24 Triac for hot runner zone HK 25 Triac for hot runner zone HK 26 Triac for hot runner zone HK 27 Triac for hot runner zone HK 28 Triac for hot runner zone HK 29 Triac for hot runner zone HK 30 Triac for hot runner zone HK 31 Triac for hot runner zone HK 32
–6X10(.1–.2–.3) Connection for heater band DH (.1–.2–.3) –6X18 Connection for thermocouples –6B5 and –6B6 –6X30 Connection for thermocouple –6B10 –6X31 Connection for thermocouple –6B11 –6X32 Connection for thermocouple –6B12 –6X36 Connection for thermocouple –6B16 –6X85(.1–.4) Connection for hot runner zones HK 1... HK 32 –6X89(.1–.4) Connection for thermocouple for hot runner zones HK 1...HK 32 –6X95 Connection for MH 1 .... DH 1 –6X96 Connection for thermocouple MH and DH –6X99(.1–.4) Dummy plug for thermocouple sockets – hot runner –6X100(.1)
8-24
Dummy plug for thermocouple sockets – melt temperature and additional controller
BA027.01.1.en