Plastic Injection

Molding Machines
Components, Systems and Service

PN#2213844 / 08.20 / HYD2005-2176

 Your Professional Partner Areas of Expertise:
Hydraulic Fluid Conditioning
for Plastic Injection Origin and Effects

Molding Machines.
of Fluid Contamination.........3

In-line Fluid
With over 8,000 employees worldwide, HYDAC is one of the leading Conditioning.........................4
suppliers of fluid technology, hydraulic and electronic equipment.
Offline Fluid
Our wide range of products, combined with our expertise in development, Conditioning.........................5
manufacturing, sales and service enables the manufacturers of plastic
injection molding machinery worldwide to overcome the most diverse Electronics, Condition
problems. Monitoring and IIoT
Our quality and environment certification to ISO 9001/2015 and ISO 18001 Technology............................6
denote first class quality and responsible m
 anagement of our resources.
Cooling Systems...................7
From the components to the system, whether in hydraulics or cooling, your
demands are our challenges: Hydro-Pneumatic
•  astest possible cycle speed
F Accumulators........................8
• Continuous, smooth operation for long periods
Accessories...........................9
• No significant downtime: quick changeovers, no major failures
• Maximum repeatability: few/no reject parts despite fine tolerances Process Filtration................10
• Low (or no) materials waste, minimal energy costs
• Long machine service life, minimized maintenance costs

Global yet local.

With 40 overseas subsidiaries and over 500 distributors and service
partners, HYDAC is your reliable partner worldwide.

Solution packages. One supplier. One contact.

Wherever you need us, we are there to help you find the most effective
solution – for every application, from components to a complete system.

Worldwide specifications and approvals.

2 PN#2213844 / 08.20 / HYD_2005-2176

Origin and Effects of Fluid Contamination
Did you know that approximately 80% of unplanned PIMM hydraulic system maintenance can be
attributed to fluid contamination?
Hydraulic and hybrid electric-hydraulic Hydraulic components
plastic injection molding machines
(PIMMs) are designed overcome
extremely demanding operating
Maintenance / service
conditions and production Cleaning work
expectations while minimizing
wasted material and energy Valve block
resources. Fluid contamination
directly effects these areas
of concern, and the use of
increasingly sophisticated
components and control
Tank breather filter
mechanisms in PIMMs has
made fluid conditioning a Filling
particularly important aspect
of strategic maintenance. Pump
Central tank
HYDAC is your partner and
a recognized global leader in
Filling
fluid conditioning. We specialize
in advanced in-line and offline
solutions such as pressure and
return filtration, independent
Cooler / heater
kidney loop filtration, dehydration
and degassing, and oil degradation
product (varnish) mitigation.

Solid Contamination Liquid Contamination Gaseous Contamination Gel-like Contamination

Origin: Origin: Origin: Origin:

• Installation contamination
• Ambient contamination
• Refilling of operating fluid
• Internal wear
• Oil ageing
Effects:
• Abrasive wear
• Increased leakage
• Component failure
• Control inaccuracies
• Blockage of control pistons
• Short fluid service life thickness
• Moisture from
the ambient air
• Cooling system leaks
• Process water/steam
• Leakage of seals
• High-pressure cleaner
• Chemical reaction
Effects:
• Corrosion
• Reduction in dynamic
viscosity/lubricating film
• Contact with surfaces
• Wear
• Changed oil properties
• Creation of acidic oil
degradation products
• Formation of sludge
• Accelerated oil ageing
• Cavitation damage
• Contact with ambient air
• Outgassing of the fluid
• Leakage of seals
• Process gas
Effects:
• Cavitation damage
• Oxidation
• Local overheating of the
fluid
• Accelerated oil ageing
• Control inaccuracies
• Risk of explosion • Leakage
• Oil ageing
• Oil mixing
Effects:
• Reduced lubrication
clearances
• Increased friction/
temperature
• Increased bearing wear
• Malfunctions in valves
• Unstable control behavior
• Damage to dynamic seals
• Blockage of filter elements
• Short filter life caused by
sludge formation
• Reduced system efficiency

PN#2213844 / 08.20 / HYD2005-2176 3

 1
In-line Fluid Conditioning
Effective filtration is imperative for maintaining hydraulic oil cleanliness, which
ensures a long life for the oil and hydraulic components, as well as a trouble-
free, cost-effective operation. Achieving this requires an understanding of critical
hydraulic component sensitivity and the appropriate filtration strategy required to
meet necessary cleanlliness levels.
The filtration concept must also conform to the hydraulic and mechanical design
limitations/restrictions of the machine, and must be closely monitored. In addition,
hydraulic systems using pumps with high dynamic flow and pressure changes,
require application-specific filter elements and housings to withstand fatigue
load. A complete selection of filter housings, elements and clogging indicators is
Inline Filters LF or DF
available.

Hydraulic actuator

1
Pump

Valve block
3
Offline Filters NF

4
3

Bypass loop pump

Circuit diagram for filtration

Return Line filters RF

Suction Strainers SF
Optimicron® Pulse
For Extreme Pressure
Fluctuations.
Stat-Free ®
No formation of electrical
potential on filter element. Low
charging of the fluid.
Stat-X®
Application in extremely critical
systems (< 100 pS/m).
Successfully avoids electrostatic
charging and discharging (ESD).

4 PN#2213844 / 08.20 / HYD2005-2176

Offline Fluid Conditioning
In-line fluid conditioning is critical to an effective strategy and relies on
the operation of the main hydraulic fluid power circuit. PIMMs generally
operate in long, non-stop production cycles, and an in-line filter
element that has reached capacity will cause the filter to relieve into
bypass or cause significant pressure loss effecting machine operability,
output and product quality. Due to the sensitivity
Offline fluid conditioning—commonly referred to as a “kidney loop”-- of components and
provides active and continuous fluid conditioning that is independent
of the main hydraulic fluid power circuit. Benefits of this type of fluid high-pressure operation
conditioning include: of PIMMs, the fluid
• Achieve and maintain exceptional fluid condition
• Optimize the service life of sensitive system components
cleanliness according
• Maximize in-line filter element change intervals to ISO 4406:2017 is
• Ensure a machine is filled with clean fluid
16/14/11 or better.

Filtration (solid)

CM Dewatering (liquid)
Filtration Station Separation of Oil Degradation
OFS-A Products (gel-like)
Degassing (gaseous)
CM
CM Condition Monitoring
Hand-held
Filter System
Filling Filtration HFS

OffLine Filter OLF 5

Main Flow
Bypass Flow Conditioning

Central Tank

CM
Bypass Flow
Conditioning OffLine Filter OLF 15 – 60
Varnish Elimination
Unit VEU-F

CM Main Flow

FluidAqua Mobil FAM

Mass Air Flow

Dehydration System
MAFH-A

PN#2213844 / 08.20 / HYD2005-2176 5

 Electronics and IIoT Technology
HYDAC specializes in linking people, objects and systems through advanced control, monitoring, and Industrial
Internet of Things (IIoT) technologies. These technologies provide optimized value networks to reduce cost and
resource usage, while improving availability, product quality and safety of hydraulic and hybrid plastic injection
molding machines.

New business models Automation of Digitization

e.g. on the basis of added value Digitally replicate or virtually represent information,
- Additional digital services networks products, functions, processes and value creation
- Digitally subscribed products
networks for which are the bases of:
- Marketing of products “as a service”, for example:
- E xtend production process automation
o Rental models
- Extend value chain automation
o Operator models
- New digital services (i.e. remote commissioning,
o Outcome-based remuneration
remote condition monitoring and analysis)
- Optimized development, simulation,
virtual testing

Flexibility
Developments such as
the desire for individualized
New
products with mass
Business Models Digitization
production pricing (thus Connectivity &
ultimately for individualized Communication
mass production), shorter and
- Instantaneous
shorter technology, innovation
identification
and product life cycles, and
- Bidirectional
resource shortage keep
Industry communication capability
applying new demands when
4.0 Connectivity, - Standardized, digital
it comes to flexibility. To this
Flexibility Communi­ interfaces and protocols
end, Industry 4.0 pursues Smart
Factory cation - Remote access to
goals such as:
Industrial
products, data and
- The adaptable factory Internet of Things information
- Plug & produce modules/ (IIoT)
- Security for connected
systems
systems
- Smart production
- Systems that can organize
and optimize themselves Information
- Smart work pieces that Increased Available
control their production Efficiency in Real Time
- Self-learning machines
and systems
- Flexibility of value
creation
networks

Increased Efficiency Relevant Information

- Productivity Available in Real Time
- Resource efficiency - Process data
o Machine availability - Condition data
o S ervice, condition-based or predictive maintenance - Smart data (e.g. action recommendations)
o Energy efficiency - Smart products
o M aterial consumption, environmental impact - Cloud
o A ssistance systems, redesigned work structure

Fluid Condition Monitoring Combination sensors

modules and systems

Compact fluid sensor modules and solutions for

assessing the fluid condition.
z Measurement data provision and system integration Pressure/temperature, distance/position/temperature, fluid level/
(e.g. central control and condition monitoring systems) temperature, temperature/humidity/conductivity/DC (HLB),
via standardised interfaces and protocols pressure/temperature/integrity of accumulator bags (BIS)
z Parameterizable threshold value monitoring z Process/condition data
z Only one process interface and one electrical interface

IO-Link Machine Condition

sensors Monitoring System
MCMS-2000
Sensors to measure pressure, differential Simple, intelligent and holistic monitoring
pressure, distance, temperature, fluid level, z Accepts fluid, component and process sensors
humidity and oil ageing z Intuitive and flexible software
z Bidirectional communication via IO-Link z Remotely monitor up to 200 machines on single dashboard
z In addition to switching output, measured values and diagnostic data z Generation of smart algorithms and alarms
provided in standardized digital format
z Connectivity via Ethernet, TCP/IP

6 PN#2213844 / 08.20 / HYD2005-2176

Filter-Cooler
Systems
Integral filtration and cooling
units with flange-mounted
motor-pump units:
• for optimum filtration
• as built-in solutions or
complete power packs
Compact products, optimized
for function, without external
connection lines
• leakage-free
• cost-effective
• tailored to the installation
space
Filter Cooler System FKEM
for in-tank mounting
Pump-Transfer Cooler Filtration
Unit UKF
PN#2213844 / 08.20 / HYD2005-2176
Cooling Systems
FLKS and FWKS Cooling Systems in their most basic form consist of a
reservoir, coolant pump, and heat exchanger. The FLKS uses the ambient
air to do the cooling job. The FWKS uses a cool water supply. Both can
be configured with temperature monitoring and control to provide a stable
coolant temperature regardless of fluctuations in heat load or cooling air/water
temperature. Control can be either electronic or mechanical.
These systems are ideal for machine tool cooling, spindles, torque motors,
servo motors, etc. They can also be used for mold cooling and almost any
application where your equipment has water jackets for cooling.
Using these FLKS/FWKS cooling systems instead of chillers in your application
will result in immediate and long term cost and energy savings.
Features
• Sizes to fit every need
• UL approved motors
• Low energy usage as
compared to chiller
• Stainless steel heat
exchanger (FWKS)
• Aluminum Bar/plate cooler
(FLKS)
• Variable speed fan or water
flow control valve
on temperature-controlled
models
• Radial fan
• Gear pump
• Wash-down duty motors
• Programmable thermostat FLKS
• In tank temperature
transducer
• Flood switch
FWKS
7
 Hydro-pneumatic
Accumulators for
Injection Molding
Applications
Bladder, piston, and diaphragm
accumulators are used in plastic
injection molding machines for
various applications:

Energy Storage:
• T o enable the manufacture of
thin wall parts, through high
Hydropneumatic Accumulators and Accumulator station
speed plastic injection Silencers are available for a wide range
• To reduce cycle time, by of design parameters:
- 250 psi to 8000 psi (16 to 550 bar)
allowing parallel operations - 0.1 pint to 350 gallons (0.075 to 1200 L)
of different functions/
movements Cycle time
• To reduce installed power, by Sequential operation reduction
Open Close
covering peak demands from mold mold by means
stored energy Fill mold of parallel
Flow

Plasticizing
Cores and operation
Pulsation Dampening: ejectors
when using an
• T
 o reduce noise emissions Time
accumulator
by minimizing pressure
Parallel operation
pulsations in the hydraulic
system Time saved
Flow

Shock Absorption:
• T o provide proportional
pressure control for pump Time
loading and pump bypass
switching
Cycle time
• To reduce shock through Injection profile using accumulator reduction
proper load sensing and
by using an
pressure spike control
accumulator
Safety Devices are avail-
Flow

Injection profile using pump only

able to complement the
Accumulators System:
• F luid side – safety and shut-
off blocks
• Gas side – Thermal fuse caps Time
and plugs, burst discs, and
gas safety valves
85 Noise reduction
without by using an
silencer
80 accumulator
Airborne sound level (dB (A))

with
silencer for pulsation
75 damping

70

65

60
05 01 00 150 200 250 300
Pressure (bar)

8 PN#2213844 / 08.20 / HYD2005-2176

Accessories Components
For Completing
CX Valves and Injection Molding Hydraulic Systems
Thermal-energy management from the mold to the platens is critical for making • Mounting technology
consistent parts. solutions including DIN3015
• CX Valves
Insulator plates are placed between the mold and the clamping plate. The
• Fluid level gauges and F
 luid
clamping plates are gun drilled for cooling water, which protects the platen,
level sensors
mold, and machine. Cold water is quickly injected into heating zones via CX
Valves, keeping the zones at the desired temperatures. • Shut-off ball valves
• Breathers
Benefits
•  aster time to thermal equilibrium for mold, platens, and tiebars
F
• Less wear and tear on machine and mold
• Platens can be worked on without burning your hands
• Less time on removal and handling of hot mold
• Consistent parts achieved faster with less waste at startup
• More stable process
• Less waste of expensive resin
DIN3015

Fluid Level Gauges & Sensors

Ball Valves

CX Valves

Breathers

PN#2213844 / 08.20 / HYD2005-2176 9

 Stainless Steel High
Pressure Inline Filter EDFR
Process Filtration HYDAC’s
EDFR
Polymer Melt Filtration provides high
A specialist area of fluid filtration is in the production and processing of
pressure
plastics.
filtration
In addition to the impurities brought in from outside and caused by the
manufacture of raw materials, the presence of gels and specks often
for Polymer
brings further problems in product quality assurance. circuit
Filtration using special filter elements made from Chemicron (metal fibre), before the
in filtration ratings of 1 and 100 μm absolute, has proven most effective production
in this field. The filter elements are pleated as standard or available in machine
customized versions.

Pellets

Specifications
• Flowrates: up to 100 gpm
• Filtration rating: 1 – 250 microns
• Press max: up to 1035 bar
• Temp max: up to 400 °C
• Connection:G3/4”, G1 1/4”, G1 1/2”
Housing Material Fiber
• Stainless Steel 1.4571
Filter Elements
• Chemicron®
• Betamicron®
• Wire Mesh

Stainless Steel Inline Filter

PFM / PFH Films

HYDAC’s Stainless Steel Inline Filter PFM, provides protection of tools on

injection molding machines and all cooling channels

PFM at Plastic Injection Molding Machines

Cooling Water Filtration
Technical Details
• Cooling channels: Ø 0,8 mm
• Pressure: 16 bar
Specifications • Temperature: 90 °C
• Flowrates: up to 35 gpm
• Filtration rating: 1 – 2000 microns
• Press max: up to 100 bar
• Temp max: up to 200 °C
• Connection:G1“
Housing Material
• Stainless Steel 1.4581
• Stainless Steel 1.4571
Filter Elements
• Chemicron®
• Wire Mesh
• Slotted Tube
• Betamicron®

10 PN#2213844 / 08.20 / HYD2005-2176

Notes

PN#2213844 / 08.20 / HYD2005-2176 11

 Global Headquarters
HYDAC INTERNATIONAL
North America Locations
GMBH
USA
Industriegebiet NORTH AMERICA HEADQUARTERS
HYDAC TECHNOLOGY CORPORATION
D – 66280 Sulzbach/Saar
Germany Filter Division
2260 City Line Road
Tel.: +49 6897 509-01 Bethlehem, PA 18017
+1.610.266.0100
Fax: +49 6897 509-577
Internet: www.hydac.com
Email: info@hydac.com HYDAC TECHNOLOGY CORPORATION
Filter System Division
Process Filter Division
Fuel Filtration Division
580 West Park Road
Leetsdale, PA 15056
+1.724.318.1100
HYDAC TECHNOLOGY CORPORATION
Cooling System Division
1051 Airlie Parkway
Denver, NC 28037
+1.610.266.0100
HYDAC TECHNOLOGY CORPORATION
HYDAC CORPORATION
Sales Office & Operations
510 Stonegate Drive
Katy, TX 77494
+1.281.579.8100
Canada
HYDAC CORPORATION
14 Federal Road
Welland, Ontario, Canada L3B 3P2
+1.905.714.9322
Mexico
HYDAC INTERNATIONAL SA de CV
Calle Alfredo A Nobel No 35
Col Puente de Vigas
Tlalnepantla, Edo Mexico
CP 54090
Mexico
+011.52.55.4777.1262
© Copyright 2020 HYDAC TECHNOLOGY CORPORATION • Plastic Injection Molding Machine Brochure
www.HYDAC-NA.com
HYDAC TECHNOLOGY CORPORATION HYDAC TECHNOLOGY CORPORATION
Electronic Division Accessory Division
Process Filter Division
2204 Avenue C
HYDAC CORPORATION Bethlehem, PA 18017
Accumulator Division +1.610.266.0100
90 Southland Drive
Bethlehem, PA 18017
+1.610.266.0100
HYDAC TECHNOLOGY CORPORATION HYDAC TECHNOLOGY CORPORATION
Hydraulic Division TechCenter
450 / 445 Windy Point Drive 430 Windy Point Drive
Glendale Heights, IL 60139 Glendale Heights, IL 60139
+1.630.545.0800 +1.630.545.0800
HYDAC TECHNOLOGY CORPORATION HYDAC CYLINDERS LLC
Mobile Hydraulic Division 540 Carson Road North
1660 Enterprise Parkway • Suite E Birmingham, AL 35217
Wooster, OH 44691 +1.205.520.1220
+1.610.266.0100
HYDAC TECHNOLOGY CORPORATION HYDAC TECHNOLOGY CORPORATION
HYDAC CORPORATION HYDAC CORPORATION
NW Sales Office & Operations NE Sales Office
1201 NE 144th St. Bldg. B • Suite 111 1660 Enterprise Parkway • Suite E
Vancouver, WA 98685 Wooster, OH 44691
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www.HYDAC-NA.com
HYDAC CORPORATION HYDAC CORPORATION
Sales Office Sales Office
5160 75 Street NW Montreal, Québec, Canada J2M 1K9
Edmonton, Alberta, Canada T6E 6W2 +1.877.539.3388
+1.780.484.4228
www.HYDACmex.com
PN#2213844 / 08.20 / HYD2005-2176