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ENGEL Injection Molding Machine Maintenance Manual 8580.772.0699M ES25 - 4000 : ENGEL Injection Molding Machine, Maintenance Manual. 8580.772.0699M (Manual, Service) ES25 - 4000 Re-issue 12-12-2005 ENGEL reserves the right to change or update information without prior notification. Due to on going product improvement andvarious customer options available, ENGEL cannot fully guarantee the accuracy of information contained in this manual. Therefore Engel accepts no responsibility in that respect. DANGER Complex machine with personal injury hazards. Do not operate machine unless you are properly trained. Read and understand the hazards outlined in chapter 3 ofthis manual. Before start-up, check safety devices as per chapter 3 - Machine safety checklist. Do not operate machine unless all interlocks/safety devices are in place and function properly. Consult your supervisor, if in doubt about machine safety . Failure to follow instructions could result in injury. WARNING! ENGEL ADVISES THE USE OF NEW,CLEAN OIL, TO ISO CODE 16/13, IN THEIR INJECTION MOLDING MACHINES. THIS LEVEL OF CLEANLINESS OR BETTER MUST BE MAINTAINED THROUGHOUT THE LIFE OF THE MACHINE. REFER TO ISO 4406 - HYDRAULIC FLUID POWER - FLUIDS - METHOD FOR CODING LEVEL OF CONTAMINATION BY SOLID PARTICLES. USEMINERAL BASED HYDRAULIC OIL WITH A VISCOSITY CLASS OF ISO VG 46 (AT 40O C) RECOMMENDED IN THE TABLE BELOW. CONTACT ENGEL CONCERNING POSSIBLE WARRANTY ISSUES IF ZINC FREE (ASHLESS) HYDRAULIC OIL IS USED IN THE INJECTION MOLDING MACHINE. THE USE OF RECYCLED OIL TO OPERATE ANENGEL INJECTION MOLDING MACHINE WILL VOID THE WARRANTY OF THAT MACHINE. These documents remain the property of ENGEL (Canada) Inc. And must not be copied without the written consent of ENGEL (Canada) Inc. The contents of this manual may neither be made known to third parties or be used for non-approved purposes. 2005 Copyright by ENGEL CANADA INC. Guelph, Ontario, : 2005 Copyright by ENGEL CANADA INC. Guelph, Ontario, MAINTENANCE: 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION - - - - - - - - - - - - - - - 1 1. MAIN MACHINE ELEMENTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. THE CLAMPING SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3. DESCRIPTION OF TOGGLE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4. CLAMP CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5. HYDRAULIC EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6. TIE-BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7. MOLD HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8. SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9. INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 10.CARRIAGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 11. PLASTICIZING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 12. INJECTION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 13. SCREW DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 14. SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 14.1. PLASTICIZING SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 14.2. TYPES OF SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 15. SCREWTIPS & NON-RETURN VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 16. NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 17. GENERAL MACHINE CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2. GENERAL MACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39 1. LEGEND FOR MACHINE SPECIFICATION TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . 2. MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. TOGGLE INJECTION MOLDING MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. TIEBARLESS INJECTION MOLDING MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . 2.3. VERTICAL CLAMP, HOR. INJ. UNIT, ROTARY TABLE, MOLDINGMACHINES. . 2.4. VERTICAL CLAMP, VERT. INJ. UNIT, ROTARY TABLE, MOLDING MACHINES . 2.5. VERTICAL CLAMP, HOR. INJ. UNIT, ROTARY TABLE ELAST MACHINES . . . . . 2.6. HORIZONTAL ELASTOMER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7. DUO PLATEN INJECTION MOLDING MACHINES. . . . . . . . . . . . . . . . . . . . . . . . 2.8. LARGE TOGGLE INJECTION MOLDING MACHINES . . . . . . . . . . . . . . . . . . . . . . 2.9. PREVIOUS MODEL LINE - SMALL TOGGLE INJECTION MOLDING MACHINES 39 40 40 45 48 54 56 57 65 69 76 3. SAFETY DEVICES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 1. MACHINE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 2. MECHANICAL SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.1. SAMPLE MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 2.2. ROTARY TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3. ROTARY TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 3.1. SAMPLE ROTARY MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . 98 3.2. SHUTTLE TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4. SHUTTLE TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4.1. SAMPLE SHUTTLE MACHINE SAFETYCHECKLIST . . . . . . . . . . . . . . . . . . . . . 102 5. SAFETY INSTRUCTION PLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 16/12/05 a MAINTENANCE: 4. INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109 1. MACHINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.INSTALLATION OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. SUNNEX ISOLATION MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. UNISORB ISOLATION MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. ADJUSTMENT OF MACHINE MOUNTS (TOGGLE MACHINE) . . . . . . . . . . . . . . 1.5. ADJUSTMENTOF MACHINE MOUNTS (TIEBARLESS MACHINE) . . . . . . . . . . 1.6. SPLIT BASE MACHINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. SPLIT BASE MACHINES - TIEBARLESS - INSTALLATION - EARLY STYLE . . . . . . 2.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. SPLIT BASE MACHINELEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . 3.1.1. Levelling the Clamp base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2. Levelling the Injection base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. SPLIT BASE - TIEBARLESS INSTALLATION - LATER STYLE . . . . . . . . . . . . . . . . 4.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. SPLIT BASE MACHINE LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. LEVELLING AND ADJUSTMENT OF MACHINE MOUNTS . . . . . . . . . . . . . . . . . 5.1.1. Levelling the Clamp base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2. Levelling the Injection base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. VERTICAL CLAMP - MACHINE LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. INSTALLING AND SET-UP OF MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. SECURING THE MOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. INSTALLING MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. SETTING CLAMP FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. SETTING MOLD PROTECTION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. MOLD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. MOLD OPEN - STROKE LIMITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. REMOVAL AND REPLACEMENT OF INJECTION SCREW. . . . . . . . . . . . . . . . . . . 13. BARREL REMOVAL AND REPLACEMENT INJECTION UNITS 80-330). . . . . . . . . 13.1. CENTERING THE 80 - 330 INJECTION UNIT - OLDER STYLE. . . . . . . . . . . . .13.2. CENTERING THE 80 - 330 INJECTION UNIT - NEWER STYLE . . . . . . . . . . . . 13.2.1. MEASUREMENT OF NOZZLE CENTERING . . . . . . . . . . . . . . . . . . . . . . . 13.2.2. SWIVELLING THE INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3. CENTERING NOZZLE - 650 & UP - PREVIOUS STYLE INJECTION UNIT . . . . 14. CENTERING THEINJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1. CENTERING & LEVELLING INJECTION UNITS - 650 & UP - LATEST STYLE 14.1.1. MEASUREMENT OF NOZZLE CENTERING . . . . . . . . . . . . . . . . . . . . . . . 14.1.2. CENTERING THE NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2. SWIVELLING THE INJECTION UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. SWIVELLING THE INJECTION UNIT - IN-LINE INJECTION UNITS. . . . . . . . . . . . . 16. ADJUSTING NOZZLE HEIGHT - VERTICAL ROTARY BRIDGE MACHINES . . . . . 16.1. TO RAISE AND LOWER THE HORIZONTAL INJECTION UNIT. . . . . . . . . . . . . 17. SCREW TIP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1. CAP SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2. MOLD MOUNTING BOLTS - U.N.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. ANTI-SEIZE COMPOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20. INSTALLATION OF HEATER BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b 109 110 111 112 113 114 115 118 118 121 121 121 123 125 125 127 127 127 129 130 132 132 133 134 135 135 136 138 142 144 145 145 146 147 148 148 149 149 151 152 154 154 156 158 158 160 161 162 16/12/05 MAINTENANCE: 5.START UP AND SHUT DOWN PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - 163 1. STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. MACHINE SHUT-DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. MANUAL TO AUTOMATIC CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. CORESAND EJECTORS SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 165 166 166 6. HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 167 1. BASICS OF HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. CONVERSION OF ENERGY IN HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.DIRECTIONAL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. INJECTION MOLDING MACHINE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 3. HYDRAULIC SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. HYDRAULIC OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.HYDRAULIC FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. HYDRAULIC FLUID VISCOSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3. FILTRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1. HIGH AND MEDIUM-PRESSURE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2. HYDRAULICSUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. HYDRAULIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. HYDRAULIC PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1. Variable Displacement Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. CHECK VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1. Pilot Operated Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3. PRESSURE RELIEF VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1. Pilot Operated Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2. Directly Controlled Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . 5.3.3. Pilot Operated Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. DIRECTIONAL CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1. Pilot Operated Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. PROPORTIONAL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.1. Proportional Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2. Proportional Flow Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3. Proportional Solenoid with Position Transducer. . . . . . . . . . . . . . . . . . . . . . . 5.5.4. Proportional Directional Control Valves (Pilot Operated) . . . . . . . . . . . . . . . 5.6. OPEN LOOPVERSUS CLOSED LOOP (MOOG VALVE) . . . . . . . . . . . . . . . . . . 5.6.1. Moog Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2. Two Stage Moog Valve With Closed Loop Position Control . . . . . . . . . . . . . 5.6.3. Three-Stage Moog Valve With Closed Loop Position Control . . . . . . . . . . . . 5.7. CARTRIDGE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8. CARTRIDGE VALVES EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9. PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10. HYDRAULIC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11. HYDRAULIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/12/05 167 168 179 184 185 200 201 204 209 211 213 221 224 224 230 231 235 236 237 238 239 243 244 245 246 247 248 249 250 251 252 253 259 262 263 265 c MAINTENANCE: 7. ELECTRICAL SYSTEM. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 271 1. ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. HOW TO READ THE ENGEL ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . 1.1.1. physical location naming convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2. Electrical Line Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3. Page and Line numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.4. Typical examples explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. THREE PHASE INDUCTION MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. MOLD HEIGHT MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. TRANSFORMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. CARDRACK POWER SUPPLY UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. SOLID STATE RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. VARISTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. SOLENOIDOPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. DC SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. FANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. RECEPTACLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1. 460 VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2. 230 VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3. 120 VOLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. TRANSDUCERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1. STROKE TRANSDUCERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2. CLAMP FORCE STROKE TRANSDUCER (LVDT) . . . . . . . . . . . . . . . . . . . . . . . 13.3. HYDRAULIC AND MOLD CAVITY PRESSURE TRANSDUCERS . . . . . . . . . . . 13.4. SCREW RPM TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5. THERMOCOUPLE TRANSDUCERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. STANDARD SOLENOID LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. SETTING MINIMUM AND MAXIMUM BALANCE ON PA88 CARD . . . . . . . . . . . . . 16. SETTING THE MINIMUM / MAXIMUM POINT FOR PRESSURE (K-VALVE) - A02 CONTROLS (30 TON - 500 TON). . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. SETTING THE MINIMUM /MAXIMUM POINT FOR SPEED (Y-VALVE) - A02 CONTROLS (30 TON - 500 TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . 19. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER -TYPE LG93 . . . . . . . . . . 20. REPLACE OR ADJUSTCLAMP FORCE TRANSDUCER - TYPE LG99 . . . . . . . . . 21. USING THE MICROGRAPH AS AN OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . . . . 22. TROUBLESHOOTING PROPORTIONAL VALVE CIRCUIT . . . . . . . . . . . . . . . . . . . 22.1. HOW TO SET UP PRESSURE VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2. TESTING CLAMP PROPORTIONALVALVE FUNCTION. . . . . . . . . . . . . . . . . . 272 274 274 275 275 275 280 285 286 289 290 290 292 293 294 295 295 295 295 295 297 298 299 300 302 302 317 325 327 329 331 332 333 335 337 339 342 8. PNEUMATIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 347 1. AIR SERVICE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 2. LUBRICATOR UNIT (OIL MIST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 9. COOLING SYSTEM. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 349 1. HEAT EXCHANGER (OIL COOLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 d 16/12/05 MAINTENANCE: 10. LUBRICATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 353 1. OIL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. GREASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. HYDRAULIC OIL AND LUBRICANT COMPARISON . . . . . . . . . . . . . . . . . . . . . . 2.2. TRABON AND VOGEL AUTOMATICGREASE LUBRICATION . . . . . . . . . . . . . . 353 356 363 363 11. PREVENTIVE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 367 1. GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. SUGGESTED LOCKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. CONTROLS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. MACHINE CHECKS AND INSPECTIONS (SEMI - ANNUAL) . . . . . . . . . . . . . . . . . . . 6. CHECKING AND ADJUSTING MACHINE LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1. ADJUSTMENT OF MACHINE MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. EUROMAP 7 TEST BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. CHECKING AND ADJUSTING MOVING PLATEN BEARING SUPPORT . . . . . . . . . 7.1. MOVING PLATEN BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. CHECKING PLATEN PARALLELISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. TIEBARLESS MACHINES - PLATEN PARALLELISM . . . . . . . . . . . . . . . . . . . . . . . . 9.1. ROTARY LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2. ADJUSTMENTS FOR MAINTAINING PLATEN PARALLELISM: . . . . . . . . . . . . . 9.3. “FLEX – LINK” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. TOGGLE MACHINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1. CHECKING PARALLELISM AND TIE BAR STRETCH . . . . . . . . . . . . . . . . . . . 10.1.1. Platen Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.2. ADJUSTING PLATEN PARALLELISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.TIE BAR STRETCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1. CLAMP FORCE CALCULATION (metric & imperial) . . . . . . . . . . . . . . . . . 10.2.2. CHECKING TIEBAR STRETCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3. Tie Bar Stretch calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.4. ADJUSTING TIEBARSTRETCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. PLASTICIZING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 368 368 369 371 380 380 380 381 381 383 384 384 385 387 389 389 389 390 392 392 393 395 396 400 12. GENERAL TROUBLESHOOTING FLOWCHARTS - - - - - - - - - - - - - - - - - - - - 405 REVISION LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 417 16/12/05 e MAINTENANCE: f 16/12/05 MAINTENANCE: 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION ENGEL injection molding machines employ a hydraulically based system to provide the extremely high clamping pressures required in the production of modernthermoplastic products. The hydraulic pump is driven by an electric motor and the plastic injection process is achieved through a screw drive mechanism. 1. MAIN MACHINE ELEMENTS: A. Machine frame with: Electric motor Pump Hydraulic unit B. Clamping unit with : Platens and Tie-bars Clamping Cylinder Toggle System Safety GateC. Injection unit with: Plasticizing Cylinder Injection Cylinder Carriage Cylinder Screw Drive Material Hopper D. Control cabinet (AC) (on machine) with: Main Connection Master Breaker Switch Motor Breaker Switch Heating Breaker Switch * Programmable Controller E. Control cabinet (separate) with: Electronic control *Programmable controller (Optional) *The programmable controller might be placed in either cabinet depending on the specific machine. 16/12/05 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION 1 MAINTENANCE: The injection molding machine basically consists of two parts; a horizontal press, and an extruder with an injectioncylinder. A frame of hollow structural design, supports the horizontal clamping press and the injection unit. The right-hand part of the frame accommodates the oil reservoir and part of the manifold system. The left-hand side provides a large drop off area to accommodate bins or conveying system. TYPICAL HYDRAULIC MACHINE TYPICAL TOGGLEMACHINE 2 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION 16/12/05 MAINTENANCE: 1 Clamp Cylinder 2 Safety Gate 3 Clamp Piston 4 Tie-bars (times 4) 5 Ejector 6 Moving Platen 7 Stationary Platen 8 Plasticizing Cylinder 9 Material Hopper 10 Injection Unit 11 Screw Drive Motor 12 Monitor and Front Faceplate 13 Alarm Light 14Part Drop-out Area 15 Carriage Piston 16 Card Rack (inside left door) 17 Master Disconnect Switch 18 Machine Mount (adjustable) Component Layout - 30/55 Ton Hydraulic Clamp 16/12/05 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION 3 MAINTENANCE: 3 4 2 6 11 12 9 15 10 11 13 17 1 14 18 8 16 1 Clamp cylinder 2 Safety gates 3Clamp piston 4 Prefill Hydraulic oil tank 5 Ejector 6 Moving Platen 7 Stationary Platen 8 Plasticizing Cylinder 9 Material Hopper 10 Injection unit 11 Screw Drive Motor 12 Monitor and front faceplate 13 Alarm light 14 Part drop out area 15 Carriage piston 16 Card rack (inside left door) 17 Master disconnect switch 18 machine mount (adjustable)Component Layout 100 Ton 4 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION 16/12/05 MAINTENANCE: 1 Clamping cylinder 2 Tie bar (x4) 3 Rear platen 4 Toggle area 5 Ejector cylinder 6 Moving platen 7 Safety gate 8 Monitor 9 Plasticizing cylinder 10 Material hopper 11 Injection unit 12 Screw drive motor 13 Master disconnectswitch 14 Card rack 15 Manual switches 16 Part drop out area 17 Machine frame 18 Machine mount (adjustable) 19 Mold height motor Component Layout 85/100 Ton 16/12/05 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION 5 MAINTENANCE: 2 1 19 4 3 5 6 15 14 9 11 8 16 17 12 10 1. Clamping cylinder 2. Toggle mechanism 3. Tiebars (x 4) 4. Ejector cylinder 5. Moving platen 6. Safety gate 7. Manual control switches 8. Purge gate 9. Plasticizing cylinder 10. Carriage cylinder (x 2) 11. Material hopper 12. Injection unit 13. Screw drive motor 14. Monitor and front faceplate 15. Part drop out area 16. Card rack 17. Carriage linear bearing (x 2) 18. Master disconnect switch 19.Machine mount (adjustable) 13 18 Component layout 200 Ton (150 - 500 Ton series) 6 1. INJECTION MOLDING MACHINE GENERAL DESCRIPTION 16/12/05 MAINTENANCE: 2. THE CLAMPING SIDE The clamping side consists of: Clamping Unit - Platens and Tie-bars. On all Engel machines, the stationary platen is mounted to the base. Theclamping cylinder platen, which is the left hand platen when standing on the operator-side of the machine, is allowed to float, to a certain extent, in order to permit tie-bar stretch during clamping. The moving platen, guided on four tie-bars, is supported with roller supports on larger machines (on smaller machines the roller supports are optional).The moving platen also contains long guide bushings which ride on the highly polished surface of the tie-bars. The clamping and opening movement of the platens is achieved either by direct hydraulic action (28 ton and 45 ton) or hydraulically activated toggle mechanism. Mold mounting and ejector hose on the platen are according to SPI standards.The stationary platen is equipped with cooling holes to minimize heat transfer from the plasticizing unit or hot runner mold into the clamp system. Clamp System - ES 30 and 55. Both machines are fully hydraulic machines with a high speed closing cylinder and a high pressure cylinder and pre-fill valve. The older type of ES25, ES28 and ES45 areclamped up with the full clamping cylinder rod and have a high speed opening cylinder. 3. DESCRIPTION OF TOGGLE SYSTEM The clamp force is generated by the means of a double folding toggle mechanism. The toggle system consists of the following parts: Crosshead Left-hand connecting fork Right-hand connecting fork Link Right LinkLeft Latches Toggle Pins The toggle pins are case hardene