Engel Service Manual - Machine: Serial No.: 167521 VC 750/150 TECH

VC 750/150 TECH
Serial No.: 167521
Service Manual - Machine

ENGEL
! WARNING!
Improper use of the machine can lead to severe injury to persons and damage
to equipment!
You must read this instruction manual carefully and familiarize yourself with
the safety precautions before operating the system or carrying out any mainte-
nance.
You must ensure that the persons carrying out the activities on the machine
have read and understood the relevant sections and chapters of the instruc-
tion manual.
ENGEL AUSTRIA GmbH

A-4311 Schwertberg
Tel.: +43.50.620.0 | Fax: +43.50.620.3609
service@engel.at | http://www.engelglobal.com
Person responsible for documentation: Harald Pichler
Version: G/11/30/6/9
Printing date: 14.4.2021
Language:Englisch
Translation of original instruction manual
The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed, trans-
mitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (§12 and §13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
© Copyright by ENGEL Austria Ges.m.b.H.
Table of contents
Table of contents
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Applicable European standards and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 General information on injection molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Machine overview Victory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Overview of safety equipment Victory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Safety equipment functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 EMERGENCY STOP buttons for plant shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Injection molding machine safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Special safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Access aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Use an abc class fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8 Safety conformity pursuant to Machine Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 Safety-conforming machine/total plant (Conformity declaration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Not safety-conforming machine/total equipment (Manufacturer declaration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.3 Machine not safety-compliant, robot not safety-compliant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.4 Machine safety-compliant, robot not safety-compliant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Leveling the injection molding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Hydraulic oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3 Cleaning after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3 Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1 Starting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Setting up for injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1 Nozzle centricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Correct crane lifting of molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1.1 Attach both mold halves at the same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.1.2 Attach each mold half individually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Correct centering of mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2.1 Standard applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2.2 Heavy molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2.3 Special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2.4 Mold anti-twist safeguard (rotational centering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Correct mounting of molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.1 Mounting both mold halves at the same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.2 Individual mounting of mold halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3.3 Factors that can affect the mold performance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4 Checking the coaxiality of the two mold halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 Setting up the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 Changing a nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5 Changing a screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6 Changing the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1
Table of contents
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Check machine - Ever-Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Cleaning of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1 Cleaning the control panel on the ENGEL control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.2 Air filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4 Maintenance of the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Moving safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2.1 Moving safety gate rear with emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.3 Nozzle safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4 Fixed gate clamping unit and injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.5 Fixed gate for delivery chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1 Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2 Lubrication instructions switchable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.3 Lubricant survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.1.1 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.1.2 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.1.3 Manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.2 Hydraulic oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.2.1 Hydraulic oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.2.2 Vent hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.2.3 Changing from zinc-based to non zinc-based oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3 Oil preheating - cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.3.1 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.4 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.4.1 Auxiliary flow filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7 Compressed air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8 Air filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9 System flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
9.1 Backing up the system flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
9.2 Defragmenting the flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.3 Software update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9.3.1 Software Update for Version 1.12.xx or newer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 VirtMould Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Start and screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Load data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.5 Change or quit VirtMould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.6 Install more machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.7 Creating a VirtMould project based on an existing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1 Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2 Removal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1 Spare part drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2 List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Plans and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2 Foundation plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3 Mold mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4 Hydraulics schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.1 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.2 Declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7 Pressure accumulator test certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Service Manual - Machine | Version G/11/30/6/9

Table of contents
Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3
Table of contents

General
General
You have decided on an ENGEL product which is produced and supplied under strictest qua-
lity controls.
This instruction manual is an important part of the injection molding machine and intended for
any staff who work with or on the machine. Keep the instruction manual throughout the service
life of the machine, and pass it on to any subsequent owners or users. It is important to inte-
grate any amendments you receive with the instruction manual.
The documentation for the injection molding machine contains:
Service manual (Commissioning, Maintenance, Spares)
Operator manual (Operations)
Technical manual (Troubleshooting)
The documentation is available in the following formats:

 printed (except Technical manual). A plan of the electric system is located in the control
cabinet.
 as online help on the control unit (except for spare parts and schematics)
 On CD in PDF format
ENGEL reserves the right to update the documentation.
! WARNING!
Improper use of the machine can lead to severe injury to persons and damage
to equipment!
Before operating the plant or performing any maintenance, you must read this
instruction manual carefully, and familiarize yourself with the safety equip-
ment.
Never use the machine without appropriate training.
We recommend that you take part in training at one of Engel's training centers.
The main aim of this manual is to describe commissioning and maintenance of the injection
molding machine.
The manual is also designed help eliminate production failures as rapidly as possible.
Information
An alarm list can be found in the index directory below *Symbols.
Information on additional equipment is located in the chapter Additional Equipment.
5
General
1 Proper Use
ENGEL products are built to the current state-of-the-art, and comply with accepted safety stan-
dards.
Note that ENGEL injection molding machines must be used for manufacturing of injection
molded parts made of thermoplastics, thermosets and elastomers only, in accordance with the
instruction manual.
To this end, make sure you follow the processing instructions given by the material manufac-
turer!
(Improper processing could lead to injury or damage to equipment!)
Installation, operations, and maintenance of this machine must be performed by staff trained
for this purpose on ENGEL machines.
For damage from improper or not as agreed use, non-observation of the specifications in the
instruction manual as well as faulty operation ENGEL GmbH is not liable.
Modifying the machine invalidates its EC conformity; you are not permitted to put the machine
into operation in this case!
1.1 Applicable European standards and regulations
98/37 EWG Machinery Directive
2006/95/EWG Low Voltage Directive
89/336/EWG EMC Directive for Electromagnetic Compatibility

92/31 EWG
93/68 EWG
EN 12100-1 Machine Safety
EN 12100-2 Machine Safety
EN 294 Machine Safety, Safety Distances
EN 201 Safety Information for Injection Molding Machines
EN 418 Machine Safety, EMERGENCY STOP Equipment
EN 60204-1 Machine Safety, Electrical Equipment for Machines
EN 61310-1 Machine Safety, Displays, Marking and Operating
EN 61310-2 Machine Safety, Displays, Marking and Operating
EN 775 Industrial Robot Safety

General
7
General
2 Text formatting
The following text formatting is used to provide a clear manual layout and to emphasize parti-
cularly important information:
! DANGER!
Information marked with this symbol points out immediate danger which can
lead to death or serious physical injury!
! WARNING!
Information marked with this symbol warns of possible danger which can lead
to death or serious physical injury!
! CAUTION!
Information marked with this pictogram warns of possible danger which can
cause injury to persons and damage to equipment!
NOTICE!
Possible dangers which can cause damage to the machine!
Information
Important information and instructions!
Example:
Practical examples for the better understanding.
Alarms and Messages are listed throughout the manual in table format, indicated by a symbol
for the alarm class, and including a description of the cause, effect, and troubleshooting infor-
mation.
See Symbols* in the index of all manuals for an alarm list

General
2.1 Screen layout

Depending on the machine configuration, the screen lengths can differ. Some screens support
scrolling. The screens are divided into functional areas.
Screens
NOTICE!
The parameters in the figures are purely incidental and should not be used as a
guide for machine set up.
9
General
3 General information on injection molding

Injection molding is the most important technique for producing molded parts. Originally deve-
loped for thermoplastics, today it can be used for more or less any kind of plastics, including
 thermosets (PF molding compounds),
 elastomers (e.g. rubber compounds),
 foaming (e.g. on polystyrene basis),
 filled and unfilled molding compounds.
The injection molding process, in one single work step, leads from the molding compound to
the finished formed part. The raw material is available to the processor as a powder or gran-
ules. The machine injects a liquid or at least a viscous material into a mold under high pres-
sure. Parts with high dimensional accuracy are produced.

General
4 Machine overview Victory

Example: VC 650/150 POWER
Clamping unit side Injection unit side
1 2 3 4 5 6 7 8 9
15 14 13 12 11 10
14
13
12
11
[1] Hydraulic oil tank

[2] Clamping cylinder
[3] Hydraulic ejector
[4] Moving platen
[5] Stationary platen
[6] Barrel with nozzle
[7] Material container
[8] Injection unit
[9] Screw drive for plasticizing
[10] Main switch
[11] Mains connection
[12] Control cabinet
[13] Control panel with screen
[14] Operator workplace
[15] Moving safety gate clamping unit side
11
General

Safety
Safety
Injection molding machines are powerful machines that create high PRESSURES - FORCES
- TEMPERATURES that can be dangerous to persons.
In order to protect persons against the danger of accidents, ENGEL machines are equipped
with safety devices.
! WARNING!
Danger of fatal injury due to moving components and high-pressure injection!
During operations never enter, or reach into, work areas with moving machine
parts.
Never manipulate, disable, or remove safety equipment.

Check safety equipment before operating the machine.
[Siehe Wartung der Sicherheitseinrichtungen auf Seite 326.]
If you notice that safety equipment is defective,:

1. stop machine operations and switch OFF the motor.
2. Stop all further activity on the injection molding machine.
3. Immediately contact the member of staff responsible for the safety of the machine.
4. Do not resume machine operations until all safety equipment is working properly.
! WARNING!
Danger of crushing due to moving components!
Do not work, or stand, underneath moving components. This applies to all
modes of operation, even if the machine is switched off.
Before working on the machine, move all moving components (e.g. robot axes)
to a safe position.
NOTICE!
Danger of damage to equipment due to improper settings!
When operating the machine, use settings that precisely match the require-
ments for safe operations of the machine, molds, and peripheral units.
ENGEL is not liable for operator errors.
Additional safety instructions found throughout this manual must be observed.
13
Safety
! WARNING!
Danger of fatal injury in case of improper maintenance!
Maintenance work and repairs to the machine must be performed by trained
and skilled staff.
You must have comprehensive knowledge of safety precautions and controls!
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Work on the machine, beyond the described activities, must be carried out by ENGEL service
engineers.

Safety
1 Accident prevention
 Always wear approved protective clothing when working on the system (safety shoes,
protective gloves, face protector, ...). Observe local safety regulations for operating
injection molding machines!
 Always keep the whole plant clean. This improves its functionality and enhances opera-
tor safety!
 Never remove danger signs or notices and labels from machines or auxiliary equipment!
 If you need to use a ladder or steps to fill the processing material container, use equip-
ment that complies with local safety regulations!
 Never enter or reach into the machine frame or work area while the machine is running!
 Never reach into the processing material infeed opening!
 Observe processing and safety instructions by the material manufacturer!
 When processing materials that can cause a health risk, always use exhaust gas equip-
ment!
 Use shut-off nozzles that comply with legal requirements!
 Switch off motors when performing work in the machine sphere of movement! Ensure
that the complete hydraulics system is depressurized. Exercise special care if you use
pressure accumulators!
 Observe the following when working in the vicinity of hot components, such as barrels,
injection molds etc:
 The nozzle must be retracted from the injection mold! Make sure the barrel nozzle is
not touching the mold!
 Danger of skin burns due to hot material exiting the injection mold if cold slug of
solidified material works loose!
 Never use injection molding machine surfaces as work surfaces!
 Never perform maintenance while the machine is running!
 Protect hoses against harmful influences such as acids and mechanical damage!
 Check all hoses and pipes to ensure that they are safe for use. If you notice leakages,
damage, or breaks in hoses or pipes, switch off the machine immediately!
 Interrupt the mains power supply to the machine before starting repairs or retooling!
Switch off at mains, and secure against switching on!
 Prevent access by unauthorized persons to the injection molding machine!
15
Safety

Safety
2 Pictographs
Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Example of labels on VC650/150 POWER
17
Safety
Prohibitory signs:
No access for unauthorized persons!
Do not walk or stand here!
No access with cardiac pacemaker or implanted defibrilla-

tors!
Working or standing below moving components and

suspended loads is prohibited!
If you use a third-party injection molding machine/guards, affix this pictograph at the required
positions. Pictographs are located in the control cabinet.
No access for forklift trucks and industrial vehicles!
No chip cards, small metal parts or watches!

Safety
Warning signs:
Hot surface
Electricity hazard
Crushing of hands
Overhead or suspended load
Crushing hazard!
Warning, highly pressurized, molten material!
Magnetic field
19
Safety
Mandatory Signs:
Read instruction manual!
Use personal protective equipment!
Use face shield!
Lifting point
Warning signs:
Entering the injection unit when in operation not allowed, otherwise attach suit-
able covers, which prevent reaching into the danger area of the clamping unit.

Safety
21
Safety
3 Overview of safety equipment Victory

Example: VC650/150 POWER
Clamping unit side Injection unit side
1 2 3
10 9 8 7 6 5 4
[1] Clamping unit side rear sliding safety gate

[2] Alarm lamp (flashes in case of alarm)
[3] Injection unit side rear safety gate
[4] Main switch and machine type plate
[5] Rating plate on inside of control cabinet door
[6] Injection unit side - front safety gate
[7] Guidelines for working on injection molding machines
[8] EMERGENCY STOP button - red
[9] Clamping unit side front sliding safety gate
[10] Injection molded parts delivery chute cover

Safety
23
Safety
4 Safety equipment functions

When the EMERGENCY STOP button is pressed, the whole injection molding plant including
the robot must switch off. When a safety gate is opened, all potentially dangerous movements
must stop. Alarm messages appear on screen.
4.1 EMERGENCY STOP buttons for plant shutdown

The EMERGENCY STOP buttons are located on the control panel of the injection molding
machine and - depending on the machine type - in the following areas:
 on the rear side of the injection molding machine
 on the robot handheld operator panel
 at the safety gate of a safeguard
 inside a safeguard
When an EMERGENCY STOP button is activated the robot and injection molding machine
motors are immediately switched OFF. Message:
EMERGENCY STOP
Cause An EMERGENCY STOP function is active, e.g. EMERGENCY STOP

button pressed, rear safety gate open
Effect The alarm lamp flashes, the current cycle and the motors are stopped
immediately.
All dangerous movements are blocked immediately.
Restarting after an EMERGENCY STOP

1. Make sure no dangerous situations exist.
2. Release the EMERGENCY STOP button by turning it clockwise.
3. Activate the Program Interruption switch to acknowledge the alarm
4. Switch on the motors
Information
The EMERGENCY STOP function is active in each mode of operation!
4.2 Injection molding machine safety gates

When opening a safety gate, all dangerous movements are blocked and a message to this
effect appears on the screen.
Clamping unit safety gate x open
Cause Safety gate has been opened
Effect All machine movements are blocked.
Remedy Close the safety gate.

Safety
Depending on the protection type, opening the rear safety gate on the clamping unit causes an
EMERGENCY STOP switch-off, or executes the same function as the operator side safety
gate.
Nozzle safety gate open
Cause Nozzle side safety gate open
Effect All injection unit movements are blocked and the cycle stops.
Remedy Close the nozzle side safety gate
25
Safety
4.3 Special safety equipment

Safety
5 Access aids
An access aid may be needed for some work on the injection unit. For example:
 Maintenance
 Repairs
 Feeding rubber band into feed opening
 Pellet change
! WARNING!
Danger due to instable access ladder!
When working or changing material at raised positions, use access aids pro-
vided by ENGEL (available as option) or stable, steady ladders suitable for the
intended application Or stable work platforms and access aids with non-slip
steps.
27
Safety

Safety
6 Behavior in case of fire
1. Keep calm
2. Alert the fire department
3. If possible, switch off the machine's main breaker)
4. Alert all persons in the danger zone
5. If possible, close all fire doors
6. Switch of any venting and/or air conditioning units
7. Contain the fire using suitable fire extinguisher
8. Provide assistance and direction to anyone actively involved in fighting the fire
6.1 Use an abc class fire extinguisher

 An ABC Class fire extinguisher is recommended due to it's versatility and advantages
over other fire fighting equipment.
 Be familiar with the instruction label attached to the fire extinguisher.
 Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.
! DANGER!
Danger of fatal injury due to electric shock!
Do not use water or foam-based fire extinguishers.
When using ABC powder fire extinguishers keep a distance of at least one
meter to electrical equipment.
Information
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:
 at your local ENGEL dealer/subsidiary, or

 contact the nearest ENGEL works
29
Safety

Safety
7 Rescue actions
Perform the following rescue actions to release trapped persons from the mold area;
note that accidents of this kind can only occur in case of gross misuse or if you disable
vital safety devices!
1. 2 persons are required to provide first-aid (both must be skilled in the use of the injection
or compression molding system).
2. One of the two rescuers must mechanically secure the machine against motions, such
as lowering or clamping, that would further endanger the victim or rescuers (moving
mold mounting plate, core-pull, ejector).
3. The second rescuer must manually move the machine to a position where the victim
can be freed.
4. Leave the danger area (mold area) with the person you have rescued.
5. Give first aid.
6. Call a paramedic.
31
Safety

Safety
8 Safety conformity pursuant to Machine Directive

The following cases are distinguished:
8.1 Safety-conforming machine/total plant (Conformity declaration)

The manufacturer delivers to the owner a safety-compliant turnkey system, a DECLARATION
of CONFORMITY and the CE mark on the system.
 The machine is thus safe for operations and ready for use.
The instruction manual for the injection molding machine contains an EC declaration of con-
formity as follows
8.2 Not safety-conforming machine/total equipment (Manufacturer de-

claration)
The manufacturer delivers to the owner a NON safety compliant turnkey system with MANU-
FACTURER's DECLARATION (in the instruction manual of the injection molding machine) and
without CE mark on the system.
 Thus the plant is NOT safe for operations and NOT ready for use.
When a stand-alone robot is delivered without safety gate, the MANUFACTURER DECLARA-
TION is also delivered.
When a safety-compliant turnkey system is supplied, a MANUFACTURER's DECLARATION
is not provided.
8.3 Machine not safety-compliant, robot not safety-compliant

If, due to a customer request, a plant (machine + robot) does not comply with safety regula-
tions according to EN 201 = injection molding machine, the owner is responsible for achieving
compliance with safety regulations.
 You are not permitted to operate the system until an authorized expert has type-
approved the machine and confirmed that safe operations are given, and until a decla-
ration of conformity has been presented, and a CE sign has been attached to the sys-
tem.
8.4 Machine safety-compliant, robot not safety-compliant

If, due to a customer request, a machine (robot only) does not comply with safety directive EN
775 Robot Safety, the owner must prove that safe operations the equipment given, or have it
approved by an authorized expert. Type approval by an authorized expert is not necessary in
this case.
 You are not permitted to operate the system until a declaration of conformity has been
presented and the CE sign has been attached to the system.
33
Safety

Installation and commissioning
Check the delivery immediately on arrival:

 Scope of delivery (refer to delivery note)
 Transport damage
 Visible defects
Have forwarding agent confirm all visible defects, and inform manufacturer in writing immedi-
ately.
1 Ambient conditions
The following ambient conditions are required on site to ensure trouble-free operation.
The machine is designed for operations in a closed room.
Note the following values in case of long-term storage and for operations.
Ambient air temperature

Minimum: +10 °C (50 °F)
Maximum: +40 °C (104 °F)
Atmospheric humidity (non-condensing!)

Minimum: 20 %
Maximum: 80 %
Altitude
Maximum 1000 m (3300 ft) above sea level).
Electromagnetic compatibility
Must correspond to the EC EMC directive (89/336/EEC)!
Cooling water
Maximum: +20° C (68° F)
Use clean cooling water only [See Cooling water on page 45.]
35
1.1 Foundations
Consult a construction expert (expert builder or structural engineer) to make sure that the
foundations fulfill the following requirements:
 Load-bearing capacity of the existing shop floor sufficient?
 Establishment of a foundation required?
Information
Observe details in foundation plan!
 Space requirements: In order to work on the machine, you must ensure that access is
possible from all sides!
 Machine weight
 Machine mounts
 Positions
 Maximum height adjustment
 External diameter

37
2 Transportation
! WARNING!
Danger of fatal injury from floating loads!
Floating load hazard!
Transportation must be performed by skilled staff familiar with transportation
of machines.
 Use lifting gear and cables with sufficient load-bearing capacity. For weight refer to type
plate on machine or to Plans and Protocols chapter (technical data, foundation plan).
 Only use the marked lifting eyes for transportation.
 The injection molding machine must be lifted and transported in a horizontal position
(side- and lengthwise). Adjust the lifting gear length accordingly.
 Make sure the cables are of sufficient length (taking the maximum spread of the cables
on the crane hooks into consideration 60°).
 Before lifting the machine, check the routing of the cables from the lifting eyes to the lift-
ing gear.
Example: Transportation sketch VC 650/150 to VC1350/180

mm
50
21
27° 27°
0741 725 04 184

Set the machine onto the machine mounts provided, and screw the adjusting spindles into the
machine mounts.
Machine mount with adjusting spindle

Adjusting spindle
Counter nut with washer
Machine frame
Machine mount
! WARNING!
Danger due to missing safety gates!
Mount the safety gates provided with the machine at the top of the fixed mold
fixing platen!
39
2.1 Leveling the injection molding machine

The injection molding machine must be set up to be completely level. For maximum height
adjustment of machine mounts, see foundation plans.
Example: VC 650/150 POWER

1 2
[1] Guide rails for moving platen

[2] Guide rails for moving injection unit
[3] Machine mounts (for position of all machine mounts see foundation plans)
Measuring equipment: Precision spirit level and level bar for latitudinal measurement.
Precision water level level bar
Leveling:
1. Check current machine level:
 Measuring area clamping unit side: Longitudinally and latitudinally over both guide
rails for the clamping unit side moving platen.
 Measuring area injection unit side: Measure longitudinally and at 90° latitudinally
over the injection unit guide rails.

2. Use the adjusting spindles on the machine mounts to level the injection molding
machine. Starting on the clamping unit side, first in longitudinal direction, and then lati-
tudinally.
 A deviation of max. 1 sub-graduation line on the precision spirit measure is permis-
sible.
 All machine mounts must rest flush against the floor and exert equal force on the
floor.
 Repeat the process if needed.
3. Tighten the counter nuts on the machine mounts.
Information
Level after commissioning; check again after a production time of approx. 4 weeks and adjust
if needed.
Repeat leveling if the machine leaves the installation position during production.
If you set the machine up at a different position later, it makes sense to number the machine
mounts to be able to use them at the same positions on the machine frame.
If machine mounts show signs of wear or defects, replacement of all pedestals on the clamping
or injection unit is recommended (to avoid the need to repeat leveling at frequent intervals).
41
2.2 Hydraulic oil filling
NOTICE!
Danger of damage to hydraulic components!
Do not mix zinc-based hydraulic oil and non-zinc hydraulic oil.
When topping up, always use the same hydraulic oil (zinc-based or zinc-free)
as used for commissioning at the ENGEL factory!
[See Hydraulic oil filling on page 107.]
2.3 Cleaning after installation

Use cleansing agent (e.g. paraffin) to remove the anti-corrosive protection applied at the works
on brightwork (e.g. rails).
NOTICE!
Danger of damage to machine components!
 Use only soft cleaning rags for cleaning; never use wire wool or hard objects.
 Clean all Plexiglas covers (do not use caustic or abrasive cleaning agents!)
 Clean grease nipples to prevent dirt entering grease cavities during lubrication.
 Carefully clean all guide rails.
 After cleaning, lightly oil the exposed metal areas.

3 Connections
Main switch, type plate and connections - overview of a VC Machine.
3
1
[1] Main switch with lock

[2] Machine type plate
[3] Connection cooling water return
[4] Connection cooling water feed
[5] Mains power supply - grommet
3.1 Electrical connections
! WARNING!
High voltage - danger of fatal injury!
A qualified electrician is required to connect the machine to the mains power
supply.
Always observe your power distributor's regulations.
43
Pay attention to:

 Foundation plans
 Circuit diagram (in control cabinet)
 Direction of rotation mains connector (clockwise!)
 Rating plate on the inside of the heavy current cabinet door
Check IP protection type for the injection molding machine's electric/electronic cabinet 54.
The power line must be routed through the wiring terminals in the electric/electronic cabinet to
the main terminals and connected to them!
Connection and main fuse according to circuit diagram.
You can connect the machine to a TN-C network or to a TN-S network.
2 4 6 N1 14 2 4 6 N1 14
-Q11 -Q11
1 3 5 N 13 1 3 5 N 13
` `
` `
PE
PE
L1 L2 L3 PEN L1 L2 L3 N PE
TN-C network TN-S network
When connecting to a TN-C network, the PE conductor must be connected to the N conductor
at the mains connection!
! WARNING!
High voltage - danger of fatal injury!
When fitting additional equipment to the injection molding machine (e.g. con-
veyor-belt, dryer etc.) ensure good conductivity of connection to electric
potential of machine! (Equipotential bonding conforming to EN)

3.2 Cooling water

Depending on the machine type, cooling water may be required for:
 Oil cooling, for cooling hydraulic oil, for hydraulics unit
 Flow controller (barrel infeed area, mold heating)
 Temperature control devices
 Water-cooled servomotors
A flexible connection to the supply line is required (use appropriate hose connectors). Note
connectors for feed and return!
Observe correct positions and connection dimensions for the cooling water connections in
foundation plans.
Information
The cooling water values in the following overview are recommendations.
Water temperature:
 Water infeed temperature max. 20 °C (68 °F) for water-cooled servo-motors
 Water infeed temperature max. 25 °C (77 °F) for standard machines
 Water infeed temperature max. 30 °C (90 °F) for machines with larger oil cooler
 Input pressure 3-5 bar (44-73 psi)
 Pressure differential between flow and return min. 1.5 bar (22 psi)
Cooling water quality:
The water must be clear, colorless and inodorous as well as free from algae, germs, fungi,
bacteria, iron, manganese, hydrogen sulfides, floating matter, suspended matter and sedi-
ments.
The values indicated in the table are basic recommendations without guarantee.
We cannot give any warranty concerning the durability of parts that come into contact with
cooling water as the aggressivity of the water depends on many factors.
Information
If the following values are unknown, or not adhered to, consult a hydro-technology expert to
obtain detailed analysis. The consultant will be able to suggest suitable approaches as
needed.
45
Overview - Cooling water values: (recommendations without warranty!)
Corrosion resistance
These values are provided as a guideline.
Water constituents Concentration
Electric conductivity maximum 500 µS/cm
Iron (dissolved) maximum 10 mg/l
Manganese (dissolved) maximally 1 mg/l
Chloride* maximum 80 mg/l
Free carbonic acids* maximum 0 mg/l
Sulfate maximum 200 mg/l
pH value maximum 6 - 8
Alkalinity maximum 2 - 18 dH
Total hardness maximum 5 - 14 dH
NH3 maximum 2 mg/l
Oxygen less and greater than 2 mg/l
Sulfite, free chloride* 5 mg/l
Free (aggressive) carbonic acids 20 mg/l
Oil maximum 1mg/l
Permissible grain size of foreign 0,1 mm (0.0039 in)

bodies
Turbidity 0 mg/l
Organic elements
Temperature increase motor maximum 15 °C (59 °F)

cooling (for servomotors only)
* Depends on temperature maximum 60°C (140 °F) and pH value
3.3 Compressed air

For machines with pneumatically actuated equipment, an air filter unit is required.
The flow direction is indicated by an arrow.

Air filter unit
2
3
[1] Shut-off valve in closed position

[2] Flow direction
[3] Manometer
[4] Feed pipe
The air filter unit with water trap removes contamination and condensation from the com-
pressed air.
A corresponding hose connection must be made from the compressed air supply line to the air
filter unit.
Check before connection if air line upstream is free from contamination (scaling, rust etc.);
blow out if needed!
The air filter unit has been factory set to ensure perfect working of the pneumatic equipment.
Details for the connection:
Connection dimension: Hose coupling 3/8”

Supply pressure: max. 10bar (145 psi)
Required operating pressure: 5 - 6 bar (72 - 87 psi)
The pneumatic system must provide a compressed air quality that complies with the following
specification:
ISO/DIN 8573-1 Quality class Values Units
Residual oil content 2 0,1 mg/m³
Residual dust content 1 0,1 mm bzw. mg/m³

(0.0039) (in)
Residual water content 4 6 g/m³

(at pressure dew point DPT) 3° (37.4°) °C (°F)
See also maintenance instructions in chapter: [See Compressed air unit on page 117.].
47

4 Commissioning
Before switching the machine on, check that all transport safeguards have been removed, and
that all installation and connection tasks have been performed correctly.
! WARNING!
Failure to follow instructions for commissioning may lead to fatal injury!
Do not commission the injection molding machine unless you have ensured
that:
 All fixed and moving covers on the injection molding machine have been correctly
screwed down and are closed.
 The plant is ready for use, and complies with safety regulations.
 There are no persons in the machine's danger area.
Information
As a general recommendation, make a backup copy of Harddisk0 for initial commissioning. If
needed, you can then copy the backup to an ENGEL-approved CF type (currently Toshiba
THNCF256MDGi) and insert [Siehe System-Flashkarte auf Seite 537.].
4.1 Starting the motor

After switching on the control voltage, and booting the control unit, you can now start the pump
motors with safety gates closed.
Motor start-up sequence:

1. Filter/cooling motor (not on small-scale machines)
2. A start-up impulse from the control unit starts the pump motor at ’Stand-by output’ (e.g.
pressure 30bar, volume 30%)
Multiple motors will always start one after the other.
Pumps on motors that are running must show stand-by pressure. Pumps for motors that
are to be started must be below the max. pressure for motor start.
3. The motor start button lights to indicate that all motors are delta connected.
4. Stand-by operations commence after the ramp-up circuitry of the motors has switched
from star to delta. An oil preheating program starts if the oil temperature is too low.
Pump overview
Pump Pressure Volume Pump on motor
Volume display for certain machine types only.
49
Information
If you press a pushbutton, without waiting for motors to enter delta phase, the motors stop
again.

Setting up for injection
The barrel, screw and nozzle need to be adjusted to match the injection mold for some injec-
tion molding processes.
! WARNING!
Danger due to hot barrel and pressurized molten material!
Danger of serious eye injury and burns to skin.
Observe the following items:
 Wear suitable protective clothing and face protector.

 Ensure that the process material is pressureless.
Information
Observe the following, before working on the nozzle, screw, and plasticizing barrel:
1. Heat barrel to operating temperature.

2. Clean the barrel with a suitable cleaning agent and purge.
1 Nozzle centricity
Nozzle centricity must be checked at maintenance interval 3, after leveling the machine, or
replacing the barrel.
Results of nozzle centricity check at manufacturing works

 Barrel: temperature approx. 200° C (390° F)
 Nozzle position: At same level as mounting surface
 Measuring equipment: Calipers, precision spirit level
 Measuring position: Vertical and horizontal from nozzle opening to centering bore on
mounting platen
 Centering tolerance: max. 0.2 mm (0.01 in)
51
3
4
[1] Measuring positions horizontal

[2] Measuring position vertical
[3] Mold mounting surface
[4] Nozzle
Readjustment is required when:

 The nozzle position is outside of centering tolerance.
 The nozzle moves laterally or vertically when building up contact pressure at the injec-
tion mold.
Procedure for injection unit 650 to 1800
The injection unit must be at a central position for adjustment without pressure build up.
1. For vertical adjustment release the barrel support. Turn adjusting nuts upward and use
the counter nuts to raise the guide rail.
Adjusting nuts Guide rail
Material cylinder sup-

port
Counter screws

2. Now loosen the fastening screws for the eccentric shaft.
Hexagon nut and eccentric shaft
Fastening screw
3. Perform the setting at the hexagon head on the eccentric shafts.

4. Then tighten the fastening screws for the eccentric shaft.
5. Advance and retract the nozzle multiple times to check centering.
6. If necessary, repeat the adjustment.
Adjusting nuts Guide rail
Material cylinder sup-

port
Counter screws
7. Turn the counter screws down and use the adjusting nuts to set the guide rail so that it
has firm contact with the barrel support. Do not raise the barrel while doing so.
8. And tighten the two counter nuts on the barrel support.
9. For horizontal adjustment loosen the 4 counter nuts for fine adjustment.
53
10. Use the 4 setscrews for fine adjustment.

Important: Make sure the nozzle is at right angles to the mold mounting position! (espe-
cially for immersion nozzles)
Setscrews with counter

nuts for horizontal fine ad-
justment
11. After completing adjustment make sure the setscrews on the opposite sides (2 each)
are screwed in and countered up to the stop!
The injection unit must be fixed!
Rough horizontal adjustment of nozzle

This adjustment is only required in case of major horizontal misalignment!
1. When adjusting, loosen the 4 fastening screws.
Fastening screws operator side and rear
2. Loosen swivel stop setscrew at rear or front of injection unit.

3. Use a suitable mounting aid to manually adjust the nozzle horizontally.
Swiveling stop
Setscrew
4. Tighten fastening screws.

5. Turn setscrew towards swivel plate and fix by means of counter nut.
The setup process can cause the injection unit to twist at the end of the nozzle stroke (stop
position of hydraulic piston).
If needed, adjust the rear piston rod:
1. Extend the nozzle to approx. 10 mm ( 0.4 in ) before the stop. (not the max. nozzle
stroke!)
Lever bolt
Coupling
Connecting rod
2. Uncouple the connecting rod by removing the lever bolt.
55
3. Advance nozzle up to stop. (max. nozzle stroke)
Connecting rod Counter nut Piston rod
4. Use the key-receiving surface to turn the piston rod until the bore in the connecting rod
is aligned with the bores on the couplings.
It must possible to insert the lever bolt smoothly!
5. Tighten counter nut.

57
2 Mount mold
Correct mounting of the injection mold helps to ensure optimum operations and greatly redu-
ces wear and tear.
Note the following additional information:

 Drawing [See Mold mounting dimensions on page 147.]
 Operator manual section: Setting the clamping unit.
 Information by mold manufacturer on mold weight, fixing system, cooling system, mold
heating, media connectors etc.
! WARNING!

! WARNING!
Danger of crushing with oversized injection molds!
Molds are not permitted to extend over the edges of the machine's mold fixing
platen.
Information
Danger of damage to mold mounting platen and injection mold!
 Use ’set-up’ mode to set the mold height and mount the mold.
 Maximum permissible tolerance for mounting surface parallelism on injection mold: 0.1
mm/m (0.001 in/ft).
 Make sure the injection mold is adequately fixed!
The fastening screws must reach at least 1.5 x thread diameter into the tapped bore on
the mold fixing platen!
 Use injection molds with a minimum side length of (s). Use of molds that are too small
can cause excessive surface pressure.
Calculate the smallest permissible injection mold side length (s) as follows:
s = 0.7 (calculation factor) x e1 (delivery chute width)
Example:
Delivery chute width e1 = 570 mm (22.44in)
s = 0,7 x 570 mm = 399 mm

(s = 0,7 x 22,44 in= 15,7087 in)

Illustration of basic principle

A
Mold mounting platen
e1
Delivery chute width
See drawing „mold mounting dimensions”
(the drawing is located in chapter: Appendix)
s
smallest, permissible injection mold side length
0,7
Calculation factor
To make best-possible use of a mold, and reduce wear and tear, both mold halves must be
mounted concentrically.
Misalignment of the mold halves increases wear and tear, and as a consequence will typically
cause wear and tear on inserts and cores.
As gravity acts in the vertical plane, the vertical alignment of the mold halves is particularly
important. As a general rule, you should attempt to achieve a misalignment of less than 0.05
mm (0.002 in). At 0.1 mm (0.004 in) or more you will typically hear some knocking on immers-
ing the guides, and some wear and tear of the tie-bars can occur. On large-capacity machines
misalignment can be far higher without causing any problems.
59
Correctly and incorrectly mounted molds
Wrong Wrong
Correct
3 2
[1] Correctly mounted mold:

Both mold halves are mounted on the mold fixing platen facing each other concentri-
cally.
[2] Incorrectly mounted mold:
The ejector side is mounted too high with respect to the nozzle-side mold half.
[3] Incorrectly mounted mold:

The ejector side is mounted too low with respect to the nozzle-side mold half.
2.1 Correct crane lifting of molds
! WARNING!
Danger from floating loads!
Floating load hazard!
Molds must be mounted only by skilled staff who are familiar with transporta-
tion of injection molds.

2.1.1 Attach both mold halves at the same time
1 2 3 4 5
Mold halves pulled Mold halves of Molds not cen- Mold halves Flexible rope or
towards each different weights tered mounted sepa- crane scales
other by rod rately
[1] When fitting both mold halves at the same time, use a rod to connect. Make sure the rod
does not displace the relative center of the two mold halves. If in doubt, mount the two
mold halves separately.
[2] If the two mold halves are of different weights, use a heavy-duty rod, and attach as
closely as possible above the center of gravity of each mold half.
[3] The lifting eye must be exactly above the center of gravity of the mold to allow the crane
to lift it as vertically as possible Always avoid lifting at an angle so that the top is flush
with the fixing platen you need to mount, but with a gap at the under side. Slight skew in
the other direction is not so serious, since you can compensate for this by skewing
slightly by lifting with the crane towards the fixing platen, until you can fit the mold com-
pletely flush.
[4] Do not mount the two mold halves separately as the separating line has to be com-
pletely closed.
[5] Use the crane to provide best possible support to the mold when mounting at center of
the mold fixing platen. You cannot position the mold to a hundredth of a millimeter using
the crane. Make sure you have a flexible connection between the crane hook and the
lifting eye (e.g. synthetic rope). However, crane scales are your best option. Crane
scales will ensure that you lift exactly the weight of the mold, and that the mold can be
mounted on the machine without any gravitational effect. The heavier the mold, the
more important it is to use crane scales. In case of heavy molds, always use crane
scales - use of crane scales for lighter molds is not a disadvantage.
61
2.1.2 Attach each mold half individually
1 2 3 4 5
Individual mold Center the If required, use First mold half Use crane
halves crane above a spacer (with centering scales to mount
mounted off the load, and pin) mounted the second mold
center avoid oblique conventionally half
pull
[1] Attach individual halves exactly above point of gravity to ensure vertical lifting by crane.
[2] When mounting the mold, position the crane exactly above the central axis of the mold
fixing platens. Oblique pull twists the mold and must be avoided.
[3] If the fastening thread is not exactly above the mold's center of gravity, fit a spacer.
[4] Mount the mold half with the centering pin first; this is typically the nozzle side, or the
rotary table side for rotary tables. You can lift the first mold half to be mounted in the nor-
mal way. The mold half is positioned above the centering pin, and there is no need to
take the mold weight into consideration. A flexible rope or crane scales give you an
advantage.
[5] The second mold half to be fitted typically does not have a centering pin, or only sup-
ports rough centering. When the mold closes, and the guide bolts are inserted, the lifting
force exerted by the crane lifting the mold half should be equal to the mold weight as far
as possible. Exerting too little lifting force, or none at all, causes the deadweight of the
mold to act on the guide bolts, and this can cause misalignment and play. In this case,
the mold half mounting position would be too low. Exerting too great a lifting force could
cause the rope to break, or cause the mold half to be mounted at too high a position.
Crane scales give you the ability to lift with precisely the deadweight of the mold half.
Read off the weight value before inserting the guide bolts. After closing the mold, but
before building up clamping and compression force, raise or lower the crane until the
crane shows exactly the weight value shown previously.
The heavier the mold, the more important it is to use crane scales. In case of heavy
molds over 200 kg (440 lb) always use crane scales - use of crane scales for lighter
molds is not a disadvantage.

2.2 Correct centering of mold
2.2.1 Standard applications
Standard applications, cen-

tered on nozzle side
A standard mold is normally centered on the nozzle side. The diameter of the centering pin on
the mold is normally 0.1 mm (0.004 in) smaller than the centering bore on the mold fixing
platen.
Centering is NOT required ejector side. As a mounting aid, you can also fit a centering pin that
is at least 0.5 mm (0.02 in) smaller on this side for individual mounting of mold halves.
2.2.2 Heavy molds

In case of heavy molds over 200 kg (440 lb) use crane scales for mounting. Without crane
scales it is very difficult to mount heavy mold halves concentrically to one another. Thus, it may
make sense to finely adjust both halves.
Information
If you decided to center both halves, you must ensure that both centering pins on the mold
are mutually true to a precision of less than 0.05 mm (0.002 in).
In this case the centering diameters of the two mold fixing platens on the machine must be
exactly true. ENGEL injection molding machine are true to < 0.1 mm (< 0.004 in) coaxially as
a factory standard. If you require greater precision, please specify this requirement with your
order.
Special case for tie-barless machines: If the max. permitted mold tilting torque on the ejec-
tor side (weight of the ejector-side mold half times the distance to the center of gravity - see
instruction manual) is exceeded, an additional support is required.
This consists of 2 additional guide shoes (one each on the operator and non-operator sides)
including supporting brackets which are either fitted to the mold surface on the moving mold
fixing platen, or directly to the moving mold half. The adjusting spindles screwed through the
supporting brackets rest on the top of the guide shoes. They cannot be connected to them as
the moving mold fixing platen, and thus the additional supports, need to lift off the guide shoes
when clamp force is built up. Set the spindles without building up clamp force, at setup pres-
sure with the mold closed. Only slightly pre-tighten the spindles. The moving mold fixing platen
is not permitted to tilt back. Check platen parallelism if needed.
63
2.2.3 Special applications

In some cases it is necessary to decide which side to center, however, the following basic prin-
ciples must be observed in all cases:
Always perform precision centering on the side where the greatest degree of accuracy is
required. Under normal circumstances, this will be the nozzle side, as the nozzle needs to hit
the nozzle contact point as precisely as possible.
If a drive or swiveling unit, e.g. a ’X-comp’ that is integrated in one of the two mold fixing plat-
ens is used, mold centering must also be at this side.
2.2.4 Mold anti-twist safeguard (rotational centering)

An anti-twist device for the mold is to be positioned on the side where mold centering (fine
adjustment) is located.
For a rotary table, you may need to position an anti-twist device for the mold rotary table side.
As the rotary table side mold half must be mounted first, if you mount the mold halves individ-
ually, it is impossible to adjust its rotation to match the nozzle side mold half.

2.3 Correct mounting of molds
! WARNING!
Molds must be mounted only by skilled staff who are familiar with transporta-
tion of injection molds.
2.3.1 Mounting both mold halves at the same time

Procedure:
1. Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray).
GREASE
2. Use a rod to connect the mold halves and mount jointly on machine. Align with the mold
fixing platen where the (more exact) centering lug of the mold is located; this is normally
the nozzle side Make sure that you lift the mold vertically with the crane. Always avoid
lifting at an angle so that the top is flush with the fixing platen you need to mount, but
with a gap at the underside. Slight skew in the other direction is not so serious, as you
can compensate for this by skewing slightly on lifting with the crane towards the fixing
platen, until you can fit the mold completely flush.
3. Insert the centering pin into the centering bore on the mold fixing platen. Adjust the mold
rotation using a spirit level if needed, and tighten this side while the mold is still being
supported by the crane.
65
4. Close the moving mold fixing platen in setup mode, and ascertain the mold height.
Leave the mold attached to the crane.
5. Then build up and relieve the clamp force about 3 times, but without opening the mold;
simply relieve the clamp force. Building up and relieving the clamp force allows for pre-
cise mutual alignment of the mold halves in the µm range. Make sure the lifting force
exerted by the crane exactly matches the dead weight of the mold. Then exert the clamp
force.
6. With clamp force built up, tighten the ejector-side mold clamping screws. The formula
for minimum reach of screws is: Screw diameter x 1.5. The property class of the screws
should be 8.8 or 10.9 Harder screws can mean danger to the mold fixing thread espe-
cially in the case of cast mold fixing platens. If using a high speed mold mounting device
build up clamp force before moving in the tensioning wedges.
7. Remove the crane and the rod, you can then open and close the mold, and start opera-
tions.
2.3.2 Individual mounting of mold halves

Procedure:

1. Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray).
GREASE
2. Move the mold half with the more precise centering pin into the machine and align flush
with the mold fixing platen. This is normally the nozzle side. Make sure that you lift the
mold vertically with the crane. Always avoid lifting at an angle so that the top is flush with
the fixing platen you need to mount, but with a gap at the under side. Slight skew in the
other direction is not so serious, as you can compensate for this by skewing slightly on
lifting with the crane towards the fixing platen, until you can fit the mold completely flush
Insert the centering pin into the centering bore on the mold fixing platen. Adjust the mold
rotation using a spirit level if needed, and tighten this side while the mold is still being
supported by the crane If rotational centering (anti-twist safeguard) is envisaged, it must
also be fitted at this side.
3. Use the crane, and preferably crane scales, to move the second mold half into the
machine, and align precisely with the second (typically ejector-side) mold fixing platen.
4. Close the moving mold fixing platen in setup mode, move crane to match the clamping
movement, and ascertain mold height. Make sure the weight value shown on the crane
scales does not change when inserting the guide rods, otherwise raise or lower the
crane slightly.
67
5. Then build up and relieve the clamp force about 3 times, but without opening the mold;
simply relieve the clamp force. Building up and relieving the clamp force allows for pre-
cise mutual alignment of the mold halves in the µm range. Make sure the lifting force
exerted by the crane exactly matches the dead weight of the mold. On tie-barless
machines, the display on the crane scales changes lightly due to frame deformation and
the accompanying lifting of the moving mold fixing platen from the guide rails when the
clamp force is built up. This effect is slightly greater on the ejector side mold half than
on the nozzle side.
6. With clamp force built up, tighten the ejector-side mold clamping screws. The formula
for minimum reach of screws is: Screw diameter x 1.5. The property class of the screws
should be 8.8 or 10.9 Harder screws can mean danger to the mold fixing thread espe-
cially in the case of cast mold fixing platens. If using a high speed mold mounting device
build up clamp force before moving in the tensioning wedges.
7. Remove the crane and the rod, you can then open and close the mold, and start opera-
tions.

2.3.3 Factors that can affect the mold performance:
1 2 3 4
Different temperatures High operating Unparallel insulat- Eccentrically
of mold halves temperature ing platens arranged cavities
[1] Different temperatures of the two mold halves lead to different heat expansion, and thus
to different dimensions. This can cause more wear and tear, and misalignment of the
injection molded parts at the parting line.
[2] In the case of high mold temperatures, the non-centered mold half can be caused to
become uncentered during the warm-up phase. This is caused by heat expansion,
especially in case of asymmetric alignment of fixing points. This would result in coaxial
displacement of the two mold halves. In this case, it is necessary to attach the non-cen-
tered half with the crane again after heating up and to lift it as precisely as possible.
Then loosen the clamping screws for this half, and repeat the mounting procedure start-
ing at the step of building up and releasing the clamp force 3 times.
[3] Ensure true parallelism and constant wall thickness of any insulating platens used.
Deviations of >0.05 mm (>0.002 in) cause uneven distribution of pressure in the mold,
and can lead to overmolding and formation of burrs on the injection molded parts. Insu-
lating platens are subject to wear and tear. Always check parallelism and wall thickness
- especially if problems occur.
[4] Eccentric alignment of cavities requires more clamp force. The further cavities in an
asymmetric layout are from the center, the more clamp force is required to prevent over-
molding. Thus, when designing the mold, attempt to arrange cavities symmetrically and
close to the center.
69
2.4 Checking the coaxiality of the two mold halves
The coaxiality of the two mold halves is fairly easy to check using the following method. For
this purpose, you need to attach 3 magnetic holders with dial gauges to the outside of the mold
half with the centering bore (not the centering pin).
Procedure:
1. Close the mounted mold halves to a point where the centering pin is about to enter the
centering bore; do not allow the two to touch. Measure the vertical parallelism of the
platens operator side. The distance of the measuring points must be approximately the
distance from the end of the guide pin to the center of the (front) guide shoe (length a).
Note the parallelism values you measured.
2. Attach one magnetic holder directly above each of the two top guide bores To measure
the lateral displacement, attach a magnetic holder to the side of the top guide bore. The
following figures assume that the bores are in the ejector side mold half. If the bores are
on the nozzle side, you must also attach magnetic holders nozzle side. Then align the
dial gages with the top of the pin which is close to being inserted, and set the display to
zero.
Detailed drawing:
Guide pins not yet
inserted

3. Close the mold in set-up mode to a point where the guide pins are inserted into the
guide holes Make sure the feelers on the dial gages do not rest in a lubrication groove
on the guide pins. Now read off the dial gage. Detract the parallelism value from the
value you read off the two top dial gages, or add the value, depending on the platen par-
allelism direction (narrower or wider at the top).
Detailed drawing:
Guide pins inserted
Example:
The top gages show a value of +0.1 mm (+0.004 in) after entering the hole. The sensor is
’pressed in’, which means that the pins are being lifted, which in turn means that the mold half
with the bores (the ejector side in this case) is too high. If platen parallelism was 0.03 mm
(0.0012 in) higher at the top than at the bottom, you would need to subtract the 0.03 mm
(0.0012 in) from the insertion value of 0.1 mm (0.004 in) that you measured. This would result
in a vertical displacement of 0.07 mm (0.0025 in) caused by mounting. A value of less than
0.05 mm (0.002 in) would be okay; wear and tear to the tie-bars can occur for displacements
of 0.1 mm (0.004 in) or more. On large-capacity machines the displacement value can be far
higher without causing any problems.
71
3 Setting up the barrel

The following section describes fitting and removing the nozzle, barrel and screw.
Spare parts must comply with technical specifications laid down by ENGEL. This is always the
case for original spare parts.
NOTICE!
Danger of damage to equipment due to improper settings!
If the maximum permitted barrel operating temperature is exceeded (+350 °C or
662 °F), the screw and barrel can distort.
If the temperature is exceeded, a written permission must be procured from the
manufacturing firm ENGEL.
Information
Observe the following, before working on the nozzle, screw, and plasticizing barrel:
1. Heat barrel to operating temperature.

2. Clean the barrel with a suitable cleaning agent and purge.
3. Refer to drawing of barrel in chapter Spare Parts.
! WARNING!


Example: Injection unit 650 to 2550
1 2 3 4 5 6 7 8
12 11 10 9
[1] Nozzle with nozzle heater and thermocouple

[2] Flange with fastening screws
[3] Barrel with barrel heating elements and thermocouple
[4] Lifting eyebolts for barrel
[5] Material hopper with traveler for discharging
[6] Locking plate for fastening the barrel
[7] Screw coupling
[8] Hydraulic injection cylinder
[9] Clamping lever for injection unit
[10] Swiveling device for injection unit with fastening screws
[11] Barrel support
[12] Tie rod for attaching to machine frame
4 Changing a nozzle
For some molds you need to fit a special nozzle instead of the standard nozzle.
Disassembly:
1. Switch off the machine motor.
Ensure that all function movements are blocked!
2. Heat the barrel and nozzle up to operating temperature.
3. Then switch off nozzle heater.
4. Dismount nozzle heating element with thermocouple.
5. Use a ring spanner to screw out the nozzle.
Assembly:
73
1. Check that nozzle and flange are clean, and clean if not (thread, sealing surface).
2. To keep the nozzle loose for future disassembly, apply a temperature resistant lubricant
to nozzle thread.
Lubricant temperature resistant: equal to/greater than: 600 °C (1112 °F)
Lubricant type: Loctite Anti-Seize 8150
3. Screw in nozzle up to stop (do not tighten!).
4. Clean the nozzle surface before fitting the heating element.
5. Fit nozzle heating element with thermocouple.
6. Use a torque wrench to tighten the screws on the heating element, paying attention to
the tightening torque. (see the following overview)
7. Switch on the nozzle heating.
8. After the nozzle and barrel have reached operating temperature, tighten the nozzle.
Information
For ceramic heating elements the screws must be tightened as follows:
Maximum application temperature of the medium to be heated 450 °C (842 °F).
DIN compliant screws912 Pretensioning in

Minimum rigidity 8.8 cold state
M5 2 Nm (1.475 lbf ft)
M6 2 Nm (1.475 lbf ft)
M8 2 Nm (1.475 lbf ft)
Information
For glow plug heating elements the screws must be tightened as follows:
Maximum application temperature of the medium to be heated = 350° C (662° F).
DIN compliant screws912 Pretensioning in

Minimum rigidity 8.8 cold state
M5 6 Nm (4.425 lbf ft)
M6 11 Nm (8.113 lbf ft)
M8 18 Nm (13.28 lbf ft)
5 Changing a screw
Due to specific plasticizing requirements for certain materials it can be necessary to use a
screw with a different kind of geometry.
! WARNING!
Danger of crushing in the screw coupling area and barrel anchoring points!
Do not reach into this area while functional motions are in progress.

1 2 3
[1] Allen screws

[2] Divided ring
[3] Screw coupling
Disassembly:
2. If you have not cleaned the barrel, clean the barrel:
 depending on the processing material use appropriate cleaning material (following
vendor's instructions for cleaning material!)
 Repeat functions Plasticize and Inject until only cleaning material exits the barrel.
Then purge.
3. Switch off screw rotation by setting decompression before plasticizing to the same size
as the shot volume.
CAUTION!
To avoid damage, set a slow speed for injection, decompression and nozzle movement.
4. Retract the nozzle as far as possible.
5. Switch off the nozzle heater and remove the nozzle heating element and thermocouple.
Nozzle heating element with thermocouple
Flange with nozzle and Allen screws
6. Switch off the heating element at the flange and remove.

7. Remove flange and nozzle by loosening and removing the Allen screws.
8. Advance the nozzle as far as possible without building up pressure.
9. To uncouple the screw, use the Plasticize pushbutton (decompression) to retract the
screw to halfway through the plasticizing stroke, and remove the split ring.
10. Advance the screw as far as possible by pressing the Inject pushbutton.
75
11. Use the Plasticize (decompression) pushbutton to move the screw coupling away from
the screw.
Bolts for uncoupling
13. Uncouple injection unit by removing bolts.

14. Manually push the injection unit back a sufficient distance and fix in place with lever.
Allen screws front
Clamping lever Allen screws rear
15. To be able to swivel out the injection unit remove the Allen screws at the front lower side
of the injection unit.
16. Loosen Allen screws rear lower side on the injection unit.
17. Swivel out the injection unit manually operator side.
18. Pull the screw out of the barrel nozzle side.
If needed, use an assembly aid to manually push the screw out of the screw coupling
area.
Assembly:
Basically follows the same steps as for disassembly but in reverse order.
When refitting the screw, additionally note the following:
1. Before fitting the flange, you must clean the Allen screws and threads on the flange.
2. Lubricate the thread and head support of the Allen screws with a temperature resistant
lubricant to facilitate disassembly in future.
Lubricant temperature resistant: equal to/greater than: 600 °C (1112 °F)
Lubricant type: Loctite Anti-Seize 8150
3. Use a torque wrench to tighten the Allen screws. To ensure that the flange lies flush
against the barrel surface, alternately tighten 2 diagonally opposed screws, and then at
90°).
4. Clean the nozzle surface before fitting the heating element.
5. Fit nozzle heating element with thermocouple.
6. Use a torque wrench to tighten the screws on the heating element, paying attention to
the tightening torque. (see Fitting the Nozzle)

7. Pay attention to tightening torque.

(See the following overview)
Information
The following tightening torques are valid for the barrel flanges for a maximum processing
temperature of 350 °C (662 °F).
Allen screw 10.9 tightening torque
M8 25 Nm (18 lbf ft)
M 10 48 Nm (35 lbf ft)
M 12 83 Nm (61 lbf ft)
M 16 202 Nm (149 lbf ft)
M 20 395 Nm (291 lbf ft)
Allen screw 12.9 tightening torque
M8 29 Nm (21 lbf ft)
M 10 57 Nm (42 lbf ft)
M 12 97 Nm (72 lbf ft)
M 16 236 Nm (174 lbf ft)
M 20 462 Nm (341 lbf ft)
77
6 Changing the barrel

For optimum adjustment of the shot volume or for cleaning (e.g. material change), you may
need to change or remove and refit the barrel.
! WARNING!
Danger of crushing in the screw coupling area and barrel anchoring points!
Do not reach into this area while functional motions are in progress.
1 2 3 4 5
[1] Locking mechanism for barrel

[2] Clamp collar on barrel
[3] Safety setscrew for clamp collar
[4] Split ring with Allen screws
[5] Screw coupling
Disassembly
2. If you have not cleaned the barrel, clean the barrel:
 Depending on the material processed, use appropriate cleaning material (following
manufacturer's instructions for cleaning material!)
 Repeat functions Plasticize and Inject until only cleaning material exits the barrel.
Then purge.
3. Switch off screw rotation by setting decompression before plasticizing to the same size
as the shot volume.
CAUTION!
To avoid damage, set a slow speed for injection, decompression and nozzle movement.
4. Advance the nozzle as far as possible without building up pressure.
5. To uncouple the screw, use the Plasticize pushbutton (decompression) to retract the
screw to halfway through the plasticizing stroke, and remove the split ring.
6. Advance the screw as far as possible by pressing the Inject pushbutton.
7. Use the Plasticize (decompression) pushbutton to move the screw coupling away from
the screw.

9. Use 2 eyebolts to attach barrel to suitable lifting gear.

10. Loosen the safety setscrew and turn the clamp collar anticlockwise through approx.
180°.
11. Open the locking mechanism as far as possible by removing the Allen screws.
Bolts for uncoupling
12. Uncouple injection unit by removing bolts.

13. Manually push the injection unit back a sufficient distance and fix in place with clamping
lever.
Allen screws front
Clamping lever Allen screws rear
14. To be able to swivel out the injection unit remove the Allen screws at the front lower side
of the injection unit.
15. Loosen Allen screws rear lower side on the injection unit.
16. Swivel out the injection unit manually operator side.
17. Switch off barrel heating.
18. Detach all cable connections from barrel to heating distribution box.
19. If needed, use an assembly aid to manually push the barrel out of the screw coupling
area.
20. Use lifting gear to pull barrel carefully away from injection unit.
Assembly:
Basically follows the same steps as for disassembly but in reverse order.
79

Maintenance
Maintenance
Regular and carefully performed maintenance of the machine based on the maintenance inter-
vals guarantees:
 Safety of operating staff
 Best possible availability and life-expectancy
 Cost savings
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Perform a visual check of the following items daily, during commissioning and during servicing:
 Good working order of safety devices.
 Check media lines for tightness and signs of wear.
 Check oil level in sight glass.
 Check for sufficient lubrication (e.g. layer of grease, or black stripes on guide rails,
unusual noises, mechanical damage).
 Check the water level in the water separator on the compressed air maintenance unit.
Drain condensation water at approx. 10 mm ( 0.4 in ).
 If available, check lubricant reservoir to ensure sufficient level of lubricant.
Top up if needed. Make sure you use the correct lubricant.
Empty the leakage oil reservoir.
! WARNING!
Danger of fatal injury due to high voltage, high pressure, and moving machine
parts!
Maintenance and repair work on the plant may only be carried out by persons
who have been trained for this activity on ENGEL machines.
You must have comprehensive knowledge of safety precautions and controls.
During servicing and maintenance work switch off the main switch and secure
it against switching on!
 Make sure that electric circuits are powerless before working on them!
 Before working on the pneumatics system, use the hand lever to shut off the supply to
the maintenance unit, and ensure that the unit is pressureless!
 Make sure hydraulic circuit is pressureless before working on it!
 Discharge pressure accumulators!
 Pay attention to cleanliness during all maintenance and repair work!
 Observe general safety and accident prevention regulations!
 Observe the instructions in the chapter Safety!
Use only original spare parts.
81
Maintenance
ENGEL is not liable in case of:

 use of incorrect utilities
 poor maintenance
 use of third party spare parts
Before commencing maintenance and repair work, check:

 scope of task and effort involved
 Are the required aids available? (tools, devices etc.)
 Required spare parts available?
Contact the service department:

 at your local ENGEL dealer/subsidiary, or
 contact the nearest ENGEL works
Information
Take care when disposing of used utilities!
Observe regulations for collecting and disposing of utilities used to run the machine.
They are hazardous to water supplies and can cause severe environmental damage.
Make sure you observe national waste disposal regulations!

Maintenance
1 Maintenance intervals
The control unit shows a digital time scale and a green progress indicator for 4 critical mainte-
nance intervals. The last 10% before a maintenance interval has elapsed are shown in yellow,
the next 10% after the interval has elapsed in red.
Maintenance intervals
Hours of operation
+ Total hours of operation
Maintenance interval 1
Days until maintenance

Maximum hours of operation before maintenance required
Hours of operation are only counted while the machine motor is switched on.
This maintenance must be carried out after 2 months, or 1440 hours of operation at the latest,
or after a certain number of kilometers covered by a functional unit (clamping unit, ejector,
screw, nozzle).
The screen displays a percentage value for the current status and the remaining days until the
next maintenance interval (day counter).
Maintenance interval 2, 3, 4
This maintenance must be performed by the preset operating hour count at the latest.
A warning message signals that a maintenance period has expired:
Maintenance interval x
Cause Maintenance required.
Effect Message only.
Remedy Perform maintenance. Reset the counter by pressing the [R] button.
(access level 10 required).
Check the maintenance interval number to see which tasks are necessary.
83
Maintenance
1.1 Maintenance schedule

The tasks listed in this schedule must be performed when the corresponding maintenance
interval for the machine expires.
Maintenance tasks 1 2 3 4
Cleaning of machine [Siehe Reinigen der Anlage auf Seite 365.] X
Visual check. X
Check media lines for tightness and signs of wear Check cables and con-
nectors for signs of damage.
Maintenance of the safety devices. X

[Siehe Wartung der Sicherheitseinrichtungen auf Seite 374.]
Lubricate guide rails. Remove excess grease. X

[Siehe Schmierung auf Seite 402.]
Perform air filter maintenance on control cabinets. X

CAUTION: Do not operate without filter. [See Air filter maintenance on
page 89.]
Check high-pressure, hydraulic hoses to ensure they are safe for opera- X
tions [See Hoses on page 104.].
Perform this task only on reaching Interval 2 for the first time. Take an oil X
sample and send it to the oil supplier for analysis. Have the oil tested for
water content and contamination. If needed, filter or change the oil based
on the supplier's recommendation. [Siehe Hydraulik auf Seite 481.]
Clean oil cooler [See Oil cooler on page 112.]. X
Check nozzle centering. X

[Siehe Einrichten zum Spritzen auf Seite 113.]
Grease screw drive thoroughly with roller/anti-friction bearing grease (only X

up to injection unit size 500). Remove excess grease.
[Siehe Schmierung auf Seite 402.].
Grease motor thoroughly if grease nipple is available (use roller/anti-friction X

bearing grease). [Siehe Schmierung auf Seite 402.]
Replace hydraulic oil (have the oil tested by your hydraulic oil vendor and X
replace oil filter if needed).
[Siehe Hydraulik auf Seite 481.]
Check machine leveling. X

[Siehe Transport auf Seite 69.]
Check sensors and machine accuracy. X

[See Check machine - Ever-Q on page 86.]

Maintenance
85
Maintenance
2 Check machine - Ever-Q

ENGEL has developed a computer-aided test and measuring system in order to check the pre-
cision of critical sensors and functions of the injection molding machine conveniently and reg-
ularly, and to perform calibration as needed.
Sensors are calibrated by performing comparative measurements with calibrated measuring
devices that comply with national standards. Critical technical characteristics of individual sub-
assemblies or sequences are tested under conditions similar to production conditions.
If measured values are outside of set tolerances, correcting measures are initialized. Mea-
sured data is visualized in tables and diagrams, and a test certificate is issued.
Customer benefit
 Checking of sensors in compliance with VDA 6.1-13.3 requirements (QA 9000)
 prevents mold sampling and production with incorrect data
 is a prerequisite for the use of statistical methods for process optimization (e.g. Expert
Control)
 guarantees the retraceability of the process data to national standards
 facilitates the exchange of data between machines
 helps to detect machine errors and wear at an early stage
 represents an important decision making basis for required maintenance
EVER-Q Performance
For new machines EVER-Q can be performed by a trained ENGEL service engineer at the fac-
tory in addition to standard tests. ENGEL recommends a test interval of 1 to max. 3 years,
where subset of all EVER-Q tests is performed annually, or all tests are performed every 3
years.
For more detailed information on EVER-Q contact our main works or your local subsid-
iary's/dealer's service department.

Maintenance
87
Maintenance
3 Cleaning of machine
The best approach to ensuring long life and high precision operations is careful and regular
maintenance of your machine.
Make sure that safety equipment is kept clean!
This contributes considerably to keeping safety equipment working and thus provides best
possible safety for operating staff.
Pay special attention to the following instructions:

 Use only soft cleaning rags for cleaning; never use wire wool or hard objects.
 Clean with the paint cleaner 968 and not with water.
 Clean all Plexiglas covers. (do not use acetone)
 Clean all pictographs and warning/instruction labels. Make sure they are clearly legible!
Replace if needed.
 Clean grease nipples to prevent dirt entering grease cavities during lubrication.
 Clean guide rails carefully and always lubricate with oil after doing so.
 Keep motors free of dust and dirt deposits to avoid interfering with cooling.
3.1 Cleaning the control panel on the ENGEL control unit
NOTICE!
Danger of operator errors while cleaning the touch screen and controls!
Switch off the control voltage before starting cleaning.
Danger of damage to controls if non-approved cleaning agents are used.
Recommended cleaning agents:

 Standard glass cleaner
 Isopropanol (Alkohol)
 Delothen (plastics cleaner)
We recommend a soft cleaning cloth for cleaning.
Solvent resistance:
The control surface of the ENGEL control unit (C30/controls) is resistant towards the following
solvents:
 Diesel, oil SAE, transmission oil
 Äthanol
 Antifreeze (Ethylenglykol)
Exception: Sodium hydroxide - causes slight, white coloring.

Maintenance
3.2 Air filter maintenance

The filter cartridge replacement interval must be determined individually based on dust con-
tamination levels and operating hours. A contaminated filter cartridge will cause the tempera-
ture in the control cabinet to increase!
! WARNING!
Danger of fatal injury due to high voltage in control cabinet!
Do not open the control cabinet to replace or clean the air filter.
Observe the following instructions:

1. Do not open control cabinet to change filter.
2. Remove the grating by lifting from underside. See following figures.
3. Clean filter cartridge by blowing out with compressed air, or replace.
NOTICE!
Danger of contamination!
Never run the machine without an air filter!
89
Maintenance

Maintenance
4 Maintenance of the safety devices

Check all machine safety devices whenever you perform maintenance tasks.
4.1 EMERGENCY STOP buttons

When EMERGENCY STOP is actuated, all motors of the machine must be switched off.
The position of the EMERGENCY STOP buttons depends on machine type:

 on the injection molding machine operating panel
 on the rear side of the injection molding machine
 on the robot handheld operator panel
 on the protection door in the safety guarding
 within the safety guarding
All EMERGENCY STOP buttons must be checked one after another as follows.
Procedure:
1. Close all safety gates
2. Switch on the motors
3. Actuate EMERGENCY STOP button
 All motors must stop immediately!
 The alarm lamp must flash.
 An EMERGENCY STOP alarm message is displayed.
 All machine movements must be blocked!
4. Release the EMERGENCY STOP button by turning it to the right
5. Activate the Program Interruption switch to acknowledge the alarm
Information
The EMERGENCY STOP function is active in each mode of operation!
91
Maintenance
4.2 Moving safety gates

Safety equipment controls and functions are described in chapter Safety. Perform the follo-
wing tests for all moving safety gates and protection doors:
 Visual check for wear and damage.
 Check fastenings, guides (for smooth running), stops and locking mechanisms by open-
ing and closing the safety gate.
 Check the switching function of the safety and/or monitoring elements (e.g. limit
switches, valves, screen flags) by opening and closing the safety gate and/or protection
door.
 Check whether all dangerous movements are stopped by opening the safety gate and/
or protection door.
NOTICE!
Danger of damage to injection molding machine!
 Dismount the injection mold if needed.

 Retract nozzle, heat material barrel to correct temperature, and purge.
 Set low speed (10%) for movements before doing so!
Procedure:
1. Close all safety gates
2. Switch on motor
3. Actuate the machine movement you want to test, and open the safety gate during the
movement
 The machine movement must stop immediately!
 The message Safety gate x open is displayed
4. Close safety gate again

Maintenance
Switching functions
Example: VC 500/110 limit switch position, safety edge in closed position
2
3
[1] Limit switch safety gate closed actuated

[2] Limit switch safety gate open not actuated
[3] Monitoring switch for hydraulic safety valve not actuated
For convenient checking of switching function of safety gates, you can access a screen to dis-
play the signals. When the safety gate is closed all screen flags in the line must be active.
Example: Screen flags safety gate clamping unit closed
Safety gate
Clamping unit safety gate
+ Hydraulic closing safety
1 2 3 4 5 6
closed
open
Error
[1] Limit switch safety gate closed actuated (Signal 1)

[2] Limit switch safety gate open not actuated (signal 0)
[3] Hydraulic safety valve open (signal 1)
[4] Safety limit switch for hydraulic safety valve not actuated (signal 0)
[5] Hydraulic safety valve closed (signal 0)
[6] Safety valve actuated (closing movement released hydraulically)
93
Maintenance
Example: Screen flags safety gate clamping unit open
Safety gate
Clamping unit safety gate
Hydraulic closing safety
+
1 2 3 4 5 6
closed
open
Error
[1] Limit switch safety gate closed (signal 0)

[2] Limit switch safety gate open (signal 1)
[3] Hydraulic safety valve open (signal 0)
[4] Safety limit switch for hydraulic safety valve actuated (signal 1)
[5] Hydraulic safety valve closed (signal 1)
[6] Safety valve not actuated (closing movement blocked hydraulically)
If the limit switches on the safety gate do not switch correctly, an error icon appears in the
Errors line for the flags in question, and an alarm:
Clamping unit safety gate x defective
Cause The two limit switches (1 and 2) on the safety gate are actuated or
deactivated simultaneously.
Effect Alarm lamp, motor stop.
Remedy Check for correct switching sequence of limit switches by opening

and closing the safety gate.
Hydraulic closing safety
When the safety gate is opened, the hydraulic safety valve closes and interrupts the hydraulic
link to the clamping cylinder. The valve switching status is monitored by a limit switch.
If the valve does not switch correctly, an alarm message is displayed:
Hydraulic closing safety defective
Cause The valve has not switched correctly within 1 second.
Remedy Check perfect switching sequence of limit switch and safety valve by
opening and closing the safety gate.

Maintenance
Hydraulic closing safety cartridge defective
Cause The hydraulic safety valve (pilot valve), which prevents a mold move-
ment when the safety gate is opened, has failed to switch.
Limit switches must move to opposite contact position within one
second when the safety gate is opened or closed.
This error also occurs as a consequence of clamping unit side
safety gate defective.
Effect The safety valve de-energizes and as a result blocks mold closing
hydraulically, the motor stops immediately and the alarm lamp
flashes.
Remedy Check the pilot valve on hydraulic closing safety; check the function
of the limit switches for diametrically opposed switching.
4.2.1 Moving safety gate rear with emergency stop function

Example: Safety gate rear side with safety edge in closed position
[1] Limit switch safety gate closed actuated

[2] Limit switch safety gate open not actuated
In the standard case the rear safety gate is only executed with two limit switches and produces
an EMERGENCY STOP function during opening. Check like EMERGENCY STOP buttons.
95
Maintenance
4.3 Nozzle safety gate

Function and components of a nozzle safety gate
Example: VC 650/110 limit switch position, safety gate in closed position
1 2 3
[1] Limit switch safety gate closed mechanically deactivated

When the nozzle safety gate is closed, all screen flags in the line must be active
Example: Screen flags safety gate closed

Nozzle safety gate
closed
+ open
Error
The limit switch is deactivated mechanically when the nozzle safety gate is closed.
Example: Screen flags safety gate open

Nozzle safety gate
closed
+ open
Error
The limit switch is actuated mechanically when the nozzle safety gate is opened.
The function movements on the injection unit are locked.
The following alarm is displayed if the limit switches do not switch correctly:

Maintenance
Nozzle safety gate defective
Cause The two safety gate signals are simultaneously ’’1’’ or simultane-
ously’’0’’.
Remedy Check for perfect switching sequence of signals by opening and clos-
ing the nozzle safety gate.
4.4 Fixed gate clamping unit and injection unit

The fixed gates must not be dismounted.
! DANGER!
Danger of fatal injury due to missing gates!
If it is necessary to remove fixed gates to perform maintenance work and
repairs, you are not permitted to operate the machine.
Observe safety instructions before starting work.
[Siehe Wartung auf Seite 347.]
After completing maintenance/repairs, always replace the fixed gate and ensure that it
is in the right place!
4.5 Fixed gate for delivery chute

The injection molding machine is delivered with the required safety gate for the delivery chute.
! DANGER!
Danger of fatal injury due to missing gates!
It must be impossible to reach into the clamping unit danger area.
If you then operate the machine without peripheral equipment, make sure you
restore the original the safety gates to their original state.
If you have dismount safety gates to support machine operations with peripheral equipment in
the delivery area (e.g. conveyor-belts, stacking devices etc.) make sure the safety measures
you take do not impact safety levels!
97
Maintenance

Maintenance
5 Lubrication
5.1 Lubrication instructions
1 1
[1] Injection unit guides and moving mold mounting platen

[2] Pump motor
1. Injection unit guides and moving mold mounting platen
Lubrication point
 Lubricate the grease point until you can see grease exit the supply side grease point
Repeat lubrication 2 - 3 times after performing functional movements (operator side
/ non operator side)
 Maintenance interval 1
99
Maintenance
2. Pump motor
Lubrication point
 Grease thoroughly if grease nipple is available (use roller bearing grease)

 Annually or every 8760 hours of operation
 Maintenance interval 4

Maintenance
5.2 Lubrication instructions switchable
5.3 Lubricant survey
Grease lubrication
OMV OMV LITHPLEX EP 2
MOBIL MOBILUX EP 2
SHELL ALVANIA EP GREASE 2
ARAL ARALUB HLP 2
ESSO BEACON EP 2
BP ENERGREASE LS EP 2
SUNOCO SUNAPLEX 992 EP
CASTROL SPHEEROL EPL 2
TEXACO MULTIFAK EP 2
DEA GLISSANDO EP 2
AGIP AGIP GR MU EP 2
TOTAL - MULTIS EP 2
- MULTIS 2
A lubricant safety fact sheet is available from the manufacturing works on demand.
101
Maintenance

Maintenance
6 Hydraulics
1 2 3 4
[1] Venting filter on hydraulic oil reservoir

[2] Hydraulic oil reservoir with filling cap, sight glass and draining screw
[3] Oil cooler
[4] Pump for oil filtration
[5] Low-pressure filter with soiling indicator (red button)
103
Maintenance
6.1 Hydraulic system
6.1.1 Pump
If a pump malfunction occurs, contact your local service engineer.
Some machines have tank shut-off valves to help remove the defective pump. If the tank shut-
off valve is not completely open, the following message appears:
Tank shut-off valve(s) closed
Cause Shut-off valve in the pump suction line is not open. Digital input F1 not
set + 24VE.
Effect Motor switches off, heating system ramps down, alarm lamp flashes.
Remedy Open the shut-off valve Check the limit switch.
Information
After fitting a pump (e.g. after repairs or replacing a pump) you must fill the pump with clean
hydraulic oil (of the same quality as in the oil tank) via the leakage oil connector (line to oil
tank) up to the top of the leakage oil screw!
6.1.2 Hoses
Hoses are subject to natural aging. This restricts their working life.
The owner of the injection molding machine must ensure that hoses are replaced at regular
intervals, even if no safety-relevant damage to the hose is evident.
The period of use must not exceed a maximum of 6 years from manufacturing date of hose.
1 2 3
[1] Fitting
[2] Insert
[3] Outer layer

Maintenance
! WARNING!
Danger of injury due to damage high-pressure lines!
All hoses on the injection molding machine must be checked at least quarterly
to ensure they are safe for use.
This test must be performed by a recognized expert.
An expert is a person who has sufficient knowledge in the field of the hydraulic hoses due to
their technical training and experience.
The expert must be familiar with the relevant health and safety regulations, accident preven-
tion rules, technology guidelines and best practices, to an extent that the expert can judge
whether hydraulic hoses are in a safe state for use.
Possible faults:
The following examples demonstrate the most important faults which require an urgent
replacement of the hoses.
 The outer layer of the hose pipe is damaged up to the insert (Chafe marks, cuts or
cracks).
 The outer layer is brittle (cracks in hose material).
 The hose pipe is deformed, or deforms in the pressureless or pressurized state, and/or
in case of bending, e.g. separation of layers, bubble formation, crushing or kinks.
 The hose pipe is leaky.
 The hose pipe slips out of the fitting.
 The fitting is damaged or deformed (strength of fitting or connection hose/fitting
impacted).
 The fitting is corroded - impact on functionality and strength.
 The product lifetime has expired (see manufacturing date on hose fitting).
Replacing hoses.
When replacing hoses the following must be observed:

 Only use original spare parts.
This helps to ensure that the hoses have the correct load-bearing capacity and that the
length and/or fittings match.
 Keep to the original installation position, do not modify hose clamps or the bend radius.
Safety instructions:
Make sure that hoses do not contact substances that can cause damage, e.g. acids, lyes, sol-
vents.
Do not use ozone-emitting lighting fixtures or devices that generate sparks in the immediate
vicinity.
Avoid reuse of hoses.
The first use of the hose can impact the hose material's characteristics so that reuse becomes
dangerous.
105
Maintenance
6.1.3 Manometer
Depending on the machine type, manometers for checking hydraulic pressure may be fitted at
various positions (e.g. for cores).
Manometer
Shut-off valve
Open the manometer shut-off valve only for the pressure test!
Then close the shut-off valve to prevent damage to the manometer!

Maintenance
6.2 Hydraulic oil change

Under normal circumstances, a hydraulic oil change must be made at maintenance interval 4.
Circumstances may dictate an oil change earlier, however.
We thus recommend having the used oil status checked at six-month intervals by your hydrau-
lic oil supplier and changing the hydraulic oil based on your supplier's recommendations!
NOTICE!
Danger to environment, danger of fire!
When draining and disposing of use oil, avoid pollution and avoid endangering
your environment. Follow local waste-disposal laws when draining and dispos-
ing of oil.
Change process:
1. Dismount the filling and venting filter
2. Use a suction pump to draw off the used oil, and drain the remaining oil via the oil drain
screw (at the bottom of the oil tank) into catchment trays
3. Dismount cleaning cover on the oil tank
4. Clean oil tank walls and floor to remove residue (e.g. with diesel oil)
5. The used oil must be disposed of legally, in line with waste-disposal laws
6. Screw in oil drain plug
7. Mount cleaning cover on the oil tank
8. Mount the filling and venting filter
9. Top up with hydraulic oil
6.2.1 Hydraulic oil filling

Do not run the machine unless it has been topped up with hydraulic oil.
Zinc-based hydraulic oil is used for commissioning at the factory. The machine is typically
delivered with an empty oil tank. Owner must use zinc-based hydraulic oil with same charac-
teristics when filling with oil or on oil change!
Information
Use hydraulic oil with approved viscosity „ISO VG46” only.
Overview Hydraulic oil zinc-based
OMV OMV HYD HLP 46
OMV OMV HYD HLP-SH46
MOBIL DTE 25
SHELL TELLUS 46
ARAL ARAL VITAM GX 46
ESSO NUTO H 46
107
Maintenance
Overview Hydraulic oil zinc-based
BP ENERGOL HLP HM 46
SUNOCO SUNVIS 846 WR
CASTROL HYSPIN AWS 46
TEXACO RANDO OIL HD C 46
DEA ASTRON HLP 46
AGIP AGIP OSO 46
TOTAL TOTAL AZOLLA ZS 46
Information
When changing the lubricant make, make sure you completely replace the hydraulic oil.
If you need to top up with lubricant other than the one employed, contact the oil vendor to
ensure miscibility.
The oil fill volume is noted on the oil type plate on the machine, or in the technical data docu-
mentation provided with the footing plan.
NOTICE!
Danger of overfilling due to residual oil in clamping unit!
If the clamping unit is closed, fill only to minimum level in sight glass.
Filling process:
1. Open the filler cap on the oil tank
2. Preferably use a filling device fitted with a fine filter of < 10 µm to fill the oil tank.
 The hydraulic oil filling must correspond to the following contamination class:
- Pursuant to DIN 51524-2: HLP
- Pursuant to ISO 4406: 16/13
- Pursuant to NAS 1638: 8/7
 The oil fill level must be in the top third of the sight glass while the clamping unit is
open, but in the bottom third when the clamping unit is closed!
3. Screw the filler cap back on the oil tank
4. Vent hydraulic system
6.2.2 Vent hydraulic system
Information
After filling/changing hydraulic oil, and after working on the hydraulics system, you must vent
the hydraulic cylinder.
How to detect air in the hydraulic system:

 Bubbling
 Jerky functional movements of clamping and injection unit
 Abnormal noises

Maintenance
Venting procedure:
1. Set maximum stroke and low values for pressure and speed (ca 20%) for functional
movements.
2. Run the machine through a complete stroke in set-up mode - 8 to 10 times in each case:
 Mold - opening/closing
 Ejector - advance/retract
 Nozzle - forward/return
 Injection/Screw retraction
3. After completing the venting process, check the hydraulic oil level and top up with
hydraulic oil if needed!
Oil level too low
Cause Hydraulic oil level too low.
Effect Machine stops active cycle, alarm lamp flashes. Motor ramps off,
heating ramps down.
Remedy Fill up with hydraulic oil, and repair any leakages.
6.2.3 Changing from zinc-based to non zinc-based oil

If you intend to change to non-zinc hydraulic oil, you must flush the system first.
NOTICE!
Danger of damage to hydraulic equipment.
Mixing of zinc-based and non-zinc hydraulic oil must be avoided.
Suitable non-zinc hydraulic oils:
Non-zinc hydraulic oil
OMV HYD HLP AL 46
MOBIL DTE EXCEL 46
SHELL TELLUS S 46
ARAL VITAM GF 46
TOTAL AZOLLA AF46
Procedure for changing from zinc-based to non-zinc hydraulic oil:

1. Drain used oil
 See the description in ’Hydraulic Oil Change’
Some 10 - 15% of residual used oil will remain in the machine!
2. Fill with non-zinc hydraulic oil
 See the description in ’Filling in Hydraulic Oil’
109
Maintenance
3. Perform all machine movements at full stroke in dry cycle (for approx. 15 minutes)
 Mold - opening/closing
 Ejector - retract/advance
 Nozzle - contact/retraction
 Injection / plasticizing
This mixes the used and new oil.

4. Repeat oil change
 Drain used oil
 Fill with non-zinc hydraulic oil
6.3 Oil preheating - cooling

If the oil temperature is below or drops below the configurable minimum temperature while the
motors are running, an oil preheating program automatically starts.
Set value
Maximum temp
Minimum temp
The oil temperature set value should always be 45 °C (113 °F)! Oil preheating will stop at this
value.

Maintenance
Shows the settings for oil preheating.

Oil heating
Oil preheating pressure Volume
On large-capacity machines a directional valve for the oil preheating is fitted (do_OilPreHeat-
ing).
Movements in manual and setup mode are permitted. In this case, the oil preheating program
stops, and restarts when the movement has been completed. However, it is not possible to
switch to automatic mode! This is released when the maximum temperature has been
reached.
Oil temperature too low for automatic mode
Cause Hydraulic oil temperature too low.
Effect Switchover to automatic mode blocked; oil preheating program start-

ing.
Remedy Wait with the motor switched on until the minimum hydraulic oil tem-
perature has been reached.
If the oil temperature on switching on the control unit is between the minimum temperature and
the set value minus hysteresis, the oil preheating program will also start. However, switchover
to automatic mode is not blocked.
You find variables (hysteresis, threshold values,...) in the variables monitor OilHeating group,
and/or when you select the OilHeating variable.
Oil temperature too high
Cause The hydraulic oil has exceeded the set maximum temperature.
Effect Machine completes current cycle, oil cooling remains switched on,
alarm lamp flashes.
After reaching the temperature for ’Maximum oil temperature with
motor stop’ („OilHeating” variable in the variables monitor), the motor
and the cooling water valve switch off.
Remedy Turn on the cooling water, check the cooling water inlet and the cool-
ing water valve, clean the oil cooler if needed.
111
Maintenance
No oil temperature change
Cause The oil temperature does not rise despite the oil preheating program
being activated. The temperature must rise by 2 °C (3.6 °F) within a
time of approx. 6min („OilHeating” variable in variables monitor).
Effect Motor stops
Remedy Check thermocouple and hydraulic system
6.3.1 Oil cooler

The oil cooler for the hydraulics is fitted in the main tank line or in a separate cooling and filter-
ing circuit depending on the machine type. Depending on the level of contamination and lime
content of the water, the cooling system requires regular cleaning.
Excessive oil temperature during machine operations is indicative of reduced cooling perfor-
mance.
Another way of detecting contamination is to measure the oil cooler flow rate.
Oil cooler type PWO
1
4
3
2
[1] Water feed

[2] Hydraulic oil
[3] Water return
[4] Electric solenoid valve
Cleaning options:
 Flushing with water removes contamination
 Allow a slightly acid solution to circulate several times against the normal water flow
direction
Use 5% phosphoric acid solution, or 5% oxalic acid solution for frequent cleaning.
After acid treatment rinse heat exchanger thoroughly with water.

Maintenance
6.4 Oil filter

The low pressure filter is part of a separate auxiliary circuit, or fitted immediately upstream of
the oil tank, and equipped with a mechanical/electric contamination warning mechanism.
You need to replace the filter element when:

 the red button pops out
 a message appears on screen
 hydraulic oil has been changed
During cold starts the red button on the indicator may pop out.
Do not push the red button back in until operating temperature has been reached.
If it immediately pops out again (indicating excessive differential pressure), make sure you
replace the filter element.
Message:
Check oil filter, check high pressure filter, check return filter, no
oil filtration,
Cause +24V not applied to digital input F2, oil filter contaminated, motor for
auxiliary flow filtration switched off.
Effect Machine finishes current cycle and stops, motor stops, heating ramps
off, alarm lamp flashes.
Remedy Check oil filter and filter motor.
Information
Exercise Caution if you only need to replace filter elements infrequently or not at all; the con-
tamination indicator may not be showing you when to change the filter. If the contamination
indicator is working properly, you can assume that the filter element is defective, or that the
bypass valve is not closing properly, possibly on account of contaminants.
113
Maintenance
Figure low pressure filter (PI 22)
Contamination indicator
(red button)
1(X)
[1] Notice
[2] Gasket
[3] Screw-on cartridge
Replace filter element:
Observe notes on filter housing label

1. Use a suitable catchment tray.
2. Use strap wrench to remove screw-on cartridge - turn anti-clockwise
3. Check whether the order number on the new screw-on cartridge matches the order
number on the type plate
4. Oil the seal on the screw-on cartridge slightly
5. Follow printed instructions to fit the screw-on cartridge
6. Press in red button
You cannot clean filter elements! Always fit new filter elements!

Maintenance
NOTICE!
Environmental hazard!
Follow waste disposal regulations when disposing of used filter elements.
Order replacement filter elements and keep in stock! [See List of spare parts on page 142.]
115
Maintenance
6.4.1 Auxiliary flow filtration

In this case, filtration and cooling of the hydraulic oil do not occur on the main line, but in a sep-
arate cooling circuit with a separate pump.
Filtration is always active while the pump motor is running, but can also be started separately
to filter fresh oil.
Oil filtration only
Filter motor monitoring active
Oil filtration only:

You can switch the program on manually; it switches on automatically when the oil level is too
low. Message:
Oil filtration active
Effect: Main motor will not start, oil filtration active.
Remedy: You may need to top up with oil, filter oil for sufficiently long period,
switch off oil filtration.
Filtering fresh oil:

1. Select ’Hydraulics overview’ screen.
2. Activate ’Only oil filtration’ program.
3. Switch on motors (only filter motor starts).
4. Run filtration for at least 3 hours.
5. Switch off the ’Oil filtration only’ program. Filter motor stops.
6. Acknowledge with ’Program interruption switch’.
7. The next time you switch the motor on, all motors will start again

Maintenance
7 Compressed air unit
! WARNING!
Danger of injury due to damage high-pressure lines!
All hoses on the injection molding machine must be checked at least quarterly
to ensure they are safe for use.
This test must be performed by a recognized expert.
An expert is a person who has sufficient knowledge in the field of the pneumatics due to their
technical training and experience.
The expert must be familiar with the relevant health and safety regulations, accident preven-
tion rules, technology guidelines and best practices, to an extent that the expert can judge
whether the compressed air lines are in a safe state for use.
Possible faults:
The following examples demonstrate the most important faults which require an urgent
replacement of the compressed air line.
 The compressed air line is damaged (wear and tear).
 The compressed air line is deformed, or deforms in pressureless or pressurized state,
and/or in case of bending, e.g. bubble formation, crushing or kinks.
 The compressed air line is leaky.
Replacing compressed air lines.
When replacing compressed air lines, the following must be observed:

 Only use original spare parts.
This helps to ensure that compressed air lines are sufficiently robust.
 Keep to the original installation position, do not modify compressed air lines or the bend
radius.
Safety instructions:
Make sure that compressed air lines do not contact substances that can cause damage, e.g.
acids, lyes, solvents.
Do not use ozone-emitting lighting fixtures or devices that generate sparks in the immediate
vicinity.
Avoid reuse of compressed air lines.
The first use of the compressed air line can impact the line material's characteristics so that
reuse becomes dangerous.
117
Maintenance
8 Air filter unit

The compressed air line must be of the same dimensions as the maintenance unit it services.
The fitting direction is indicated by an arrow (direction of flow).
! WARNING!
Danger due to accidental functional movements.
Before commencing maintenance and repair work, close the shut-off valve on
the air maintenance unit.
The air maintenance unit was factory set to ensure perfect working of the
pneumatic equipment and must not be modified.
Air filter unit
2
1
3
4
8
5
6
[1] Shut-off valve

[2] Hand wheel
[3] Flow direction
[4] Manometer
[5] Filter tray
[6] Display for the condensate level
[7] Condensate drain screw
[8] Feed pipe
Draining condensate:
Once a condensate level of approx. 10 mm (0.4 in) below the filter element has been reached,
you must drain the condensate manually.
1. Use a suitable catchment tray.

2. Turn the condensate drain screw counterclockwise (viewed from underneath). This
drains off the condensate.

Maintenance
3. Then tighten the condensate drain screw by turning it clockwise.

4. Dispose of condensate legally, in line with waste-disposal laws.
Change the filter cartridge in case of low volume flow despite constant pressure settings or
after 1000 hours of operation.
Replace or clean the filter cartridge:

1. Close the shut-off valve.
2. Venting the system and devices.
3. Turn the filter tray anti-clockwise (viewed from underneath).
4. Now unscrew and remove the filter tray anti-clockwise.
5. Clean the filter cartridge with water or soap suds (max. 60 °C / 142 °F) or cleaning sol-
vent (aroma free).
6. If needed, replace the filter cartridge.
7. Mount the components in reverse order (hold the new filter cartridge at the bottom end
only).
119
Maintenance

Maintenance
9 System flash card

The system flash card (harddisk0) mainly contains the system software, machine software and
various datasets.
9.1 Backing up the system flash card

As a general recommendation, make a backup copy of ’harddisk0’ for initial commissioning. If
needed, you can then copy the backup to an ENGEL-approved CF type (currently Toshiba
THNCF256MDGi) and insert.
You can copy the rear system flash card (harddisk0) to an available network drive or to the
front flash card in the data dialog:
1. On the data dialog page press Setup and System Flash card.
Data dialog
Active parts data set ENGEL standard
Data set attributes

Name
System name
Author
System flash card
Save flash card
Available drives \harddisk1
Directory
Cancel Help Save
2. Select available drive.

The flash card must be empty for saving on ’harddisk1’.
3. Execute with Storing
Information
Pay attention to the free storage capacity on the front flash card. This must be at least equal
to the capacity of the rear flash card (128MB, 256MB, ...).
121
Maintenance
9.2 Defragmenting the flash card

Frequent write operations on ’harddisk0’ can lead to worsening fragmentation. During longer
operations this can considerably slow down operations, and even cause the control unit to fail.
For EC/CC200 control units you should defragment ’harddisk0’ at maintenance interval 4
(8000 hours of operation).
The system flash card is fitted at the rear of the screen.
Control panel computer CC200 - Rear side:
System flash card
The system flash card is located in the central processing unit in the control cabinet.
Central processing unit EC200
System flash card 256 MB

Maintenance
Procedure for defragmenting ’harddisk0’:
! WARNING!
Switch off at main switch and secure against re-enabling.
These tasks must be performed by a qualified technician.
1. Remove the system flash card (harddisk0) from the machine control unit, and back up
on a PC.
2. Format the system flash card.
3. Copy the backup of Harddisk0 from the PC to the system flash card, and reinsert into
machine control unit.
CAUTION!
Note correct way of inserting flash card.
4. Close the control cabinet doors.
9.3 Software update

A software update is required on purchasing an option or changing to a more recent version of
the machine software. Software updates for the machine (update) and robot (robot update) are
separate.
The update file can be provided by email, downloaded from the ENGEL FTP server, on a Com-
pact Flash card or USB stick.
If you receive the update by email or as a download from the ENGEL FTP server, it will be in
the form of a packed (ZIP) file. You need to unpack the file on a compact flash card or a USB
stick.
Procedure for creating an Update - Compact Flash:
You need a PC with a compact flash card reader for this, and a formatted, and empty compact
flash with at least 256 MB memory. [See Formatting a compact flash or USB stick: on
page 124.]
1. Copy the Zip file (xxxxxx_update.zip or xxxxxx_robotupdate.zip) to the desktop.
2. Insert the compact flash card into the compact flash card reader.
3. Double click the Zip file and extract on the compact flash.
 In the Program WinZip (or similar tool), select all files.
 Click on extract.
 Extract to: Select drive with compact flash (enable checkbox ’Use path’ ).
 For the execution click on Extract.
4. In the Windows explorer execute ’Eject change data carrier’.
Do not remove the compact flash until ejecting has been complete without error.
Procedure for Update - USB-Stick:
You need a PC with a USB interface, and a formatted and empty USB stick with at least 256
MB memory for this. [See Formatting a compact flash or USB stick: on page 124.]
1. Copy the Zip file (xxxxxx_update.zip or xxxxxx_robotupdate.zip) to the desktop.
2. Insert the USB stick into the USB slot.
123
Maintenance
3. Double click the Zip file and extract on the USB stick.
 In the Program WinZip (or similar tool), select all files.
 Click on extract.
 Extract to: Select drive with USB stick (enable checkbox ’Use path’ ).
 For the execution click on Extract.
4. In the Windows explorer execute Eject change data carrier.
Do not remove the USB stick until ejecting has been complete without error.
Example of extracted Zip files on flash card or USB stick:
Example as of V1.12:xx; machine and robot update
Formatting a compact flash or USB stick:

The Compact Flash card or USB stick must be formatted to ensure an error-free update.
You need administrative privileges on the PC.

1. Plug the compact flash or USB stick (at least 256MB) into the PC.
2. Open Windows Explorer.
3. Right click the compact flash or USB stick drive.
4. Select Format.
5. Format with the FAT file system.
9.3.1 Software Update for Version 1.12.xx or newer

The update procedure for software version V1.12.xx or higher automatically creates backup
files for the machine. The storage medium with the update files is also the backup medium.
[See Restoring a software backup: on page 126.]
Software updating:
1. Insert the compact flash or USB stick with the update into the machine.

Maintenance
2. In the data dialog, select the screen key Setup - Software update.
Data dialog
\harddisk0 Active parts data set ENGEL standard
Data set attributes

Name
System name
Author
System flash card
Software update
3. The control unit will display the available drive with the update.
Software update
Available drives \harddisk1 for compact flash
Cancel Help Execute \usbbulk0 for USB stick
4. Press Execute to confirm and launch the update:

 Store the parts data set and the machine data set on ’harddisk0’/Data (name the
parts data set BACKUP_xxxxx).
 Create a full backup of ’harddisk0’ on the update medium (can take a few minutes).
 Software Update.
 Delete the update files from the update medium.
 Restart twice (can take up to 15 minutes).
Some messages may be output in the data dialog window during the update:
No valid update found
 No update medium plugged into machine.

 The update medium has an incorrect file structure; the root directory can contain only
the directories update or robotupdate.
Update failed, incorrect serial number!
 The update is not intended for this machine!
Update failed, not enough free memory!
 The backup storage medium for ’harddisk0’ does not have enough free memory!
Error occurred during update (see log files)!
 Update interrupted or a software error has occurred! Please check the HMI log entry in
update.log and contact ENGEL Service.
 HMI log entry - update.log
Open screen page Setup and select screen key Screens.
125
Maintenance
In the screens window, select Version display and press OK to confirm.

Select the HMI log entry tab and the update.log screen key.
Version display
Version information License informati- HMI log entry
to top to bottom
The update.log file documents all procedures performed by a software update.
Restoring a software backup:

If the software update has failed, and if the machine or robot are malfunctioning, you will need
to restore the backups.
! WARNING!
Switch off at main switch and secure against re-enabling.
These tasks must be performed by a qualified technician.
Restoring the ’harddisk0’

 Flashcard
If you use a compact flash as your update source, the backup will be bootable (original
copy of ’harddisk0’). You need to plug the compact flash into the slot for ’harddisk0’
(operating control panel computer CC200 or central processing unit EC200); the control
unit will now boot with the software version that existed prior to the update.
 USB stick
If you used a USB stick for the update, the backup will be in a subdirectory called back-
up_hd0. Use a PC to copy the content of the folder to a compact flash, and insert the
card into the ’harddisk0’ slot.
Read parts data and machine data:

1. On ’harddisk0’ select the Data directory.
2. Load the ENGEL machine data set.
3. Switch the control voltage off and back on.
4. Load the parts data set (BACKUP_xxxxx).

Maintenance
Restoring the compact flash analog cards (Type AF only455)

A backup of the analog card software will only be available if you updated the analog card! If
no backup file is available, an update of the analog cards has not occurred.
The backup file will be in the root directory as _analogcardbackup. All analog cards in a
machine use the same software, so you can restore the same backup.
Procedure:
1. Copy the backup file _analogcardbackup to the PC.
2. Remove the compact flash from the analog card.
3. Plug the compact flash into the PC (use a compact flash card reader) and delete all data
from the compact flash.
4. Copy the content of the backup file _analogcardbackup to the compact flash.
5. Insert the compact flash into the analog card.
127
Maintenance

Options
Options
1 VirtMould Program
This simulation program allows users to visualize the CC200 control unit on their PCs. Create
and process tool data and sequences independently of machine controls. The current settings
support VirtMould test runs.
When you buy the program, you receive a license for transferring datasets between the
machine and the VirtMould. The simulation is identical to the machine software.
1.1 System requirements

Operating system Windows 2000 or Windows XP
Processor > 1 Ghz
Memory 512 MB RAM recommended
Hard disc space for VirtMould installation approx. 80 MB, plus approximately 100 MB per
machine
Monitor resolution 1280 x 1024 Pixel recommended
Compact Flash Reader
CD-ROM
Information
Before starting the VirtMould close all other applications.
1.2 Installation
The VirtMould CD has a README.htm file with a precise installation guide.
After basic installation (Basic Components, VirtMould), the following window appears:
Install Virtual Machines

Select the required machine on the Source page (left), and press [Install]. Files are copied to
your computer, and then displayed on the Destination page (right).
In order to uninstall a machine from the PC, select the machine in the right-hand panel. Then
press [Remove].
Finish the installation process by pressing [Exit].
129
Options
D:\C2K
VM_314563 VM_314560
VM_315550
VM_324561
You can call the Install Virtual Machines window at any time later. To do so, select Programs/
ENGEL VirtMould/Install VirtMould in your PC's Start menu.
1.3 Start and screen structure

After the installation, an icon with the name ’’ENGEL VirtMould’’ is created on your computer
desktop.
ENGEL VirtMold
It is also possible to start the program by selecting Start/programs/ENGEL VirtMould/

ENGEL VirtMould.
When the program loads, it displays a dialog box where you can select the machine. This is
mandatory for using multiple machines. Select the machine you need, and press [Start] to
continue.

Options
Selection window
When the simulation is up and running, 3 windows are visible. VirtMould controls are identical
to those for the actual machine. Use the PC mouse to navigate the screen.
Sample view:
1 2
1. Control unit user interface

2. Panel of switches
3. Machine simulation
1.4 Load data set

In order to use a machine parts data set in the simulation, you need a Compact Flash Reader
on the PC.
In the VirtMould ’’Data dialog’’ all PC drives (including network drives) are available to you, to
support managing or archiving of parts datasets.
On saving data, VirtMould automatically creates a ’’DATA’’ folder in the root directory of the
current drive. To view the data sets later, make sure you do not move the folder to a subdirec-
tory.
131
Options
Example:
Data dialog
c:\ Active parts data set: Screw cap_small
c:\ Data set attributes

Screw cap_small Name Screw cap_small
Cup Author
1. Storing the parts data set for the machine on a Compact Flash.
2. Insert Compact Flash into the PC reader.
3. Select the Compact Flash Reader drive via the ’’Data Dialog’’ in VirtMould.
4. Load the data set in VirtMould, and then edit.
5. To back up the dataset select any drive in the ’’Data dialog’’ save.
To read the changed parts data set on the machine, proceed in the reverse order.
1.5 Change or quit VirtMould

This icon appears on the right side of the toolbar to indicate that a simulation is running .
Change
Open the icon with the right mouse key and select [Stop machine].
Open the icon again, and select [Select Machine ...]. A machine start selection dialog
appears. [See Selection window on page 131.]
Select a new machine and press [Start].
Finish
Click the VirtMould icon in the toolbar and select [Exit]. Double right-clicking the VirtMould
icon will also close the simulation.
1.6 Install more machines

If you purchase another VirtMould, you will only need to install the machine. To do so, insert
the CD ROM into the computer and select Start Menu Programs/ ENGEL VirtMould/Install
VirtMould. Installation procedure: [See Install Virtual Machines on page 129.]
1.7 Creating a VirtMould project based on an existing machine

VirtMould Version V2.1.11.1 or later lets you create a VirtMould project based on an existing
machine with a CC200 or EC200 control unit.
To do so, first create a copy of the System flashcard harddik0 on a storage medium (flashcard,
USB stick). Then connect the medium with the PC or laptop where VirtMould is installed, and
launch the Copy machines program. This program generates a VirtMould project based on
the system flashcard
Procedure for copying the system flashcard:

1. Insert the medium into the machine, ensuring you have enough free space on the
medium.

Options
2. Change to the Data dialog screen and press Setup System Flashcard
Data dialog
/harddisk1 Active parts data set STARTUP
/harddisk1 Data set attributes

Name
System name
Author
Production date
Change author System flash card
Change date
Software update
Description License update
Read machine data

Machine Number
Write machine data
Display active machine data
Parts data Edit Setup View
3. A dialog box appears. Select the available drive to which you wish to copy the system
flashcard. If you type a name for Directory, the control unit will create a folder on the
drive and copy the system flashcard to that folder. If you do not enter a folder name, the
control unit will write to the root directory of the medium. Press Save to start copying.
Save flash card
Available drives \harddisk1

Directory
Cancel Help Save
4. The Save Flash dialog appears.

Back-up Flash
/harddisk1//
Cancel
5. The dialog box disappears as soon as the copying process is completed.
Procedure for installing the VirtMould project

1. Boot your PC.
2. Attach the medium with the system flashcard to your PC.
3. Launch the Copy machines program. To do so, press Start -> Programs -> ENGEL Vir-
tual Training Machine -> Copy machines.
133
Options
4. The Install Virtual Machines window appears
314563 VM_314560
VM_315550
VM_324561
5. For Source, select the drive containing the medium with the system flashcard copy. If
you created a directory, you must select that directory. The number of the machine from
which you copied the system flashcard is displayed.
E:\
314563 VM_314560
VM_315550
VM_324561
6. Check the check box next to the machine number, and then press Install. A DOS box
appears, and the installation procedure starts.
7. The DOS box is closed when the installation is completed. You can now click on the Exit
button to quit the Install Virtual Machines program.
After successfully installing the VirtMould project, launch VirtMould and select the required
machine in the selection window.

Options
135
Options

Disassembly
Disassembly
Before transporting the machine, the robot and peripheral units must be dismounted. Refer to
the vendor's instructions to do so.
! WARNING!
Danger of fatal injury in case of improper dismounting!
Skilled staff are required to dismount the machine.
You must have comprehensive knowledge of safety precautions and controls!
Main switch, type plate and connection overview for VC Machine.
3
1
[1] Main switch with lock

[2] Machine type plate
[3] Connection cooling water return
[4] Connection cooling water feed
[5] Mains power supply - grommet
137
Disassembly
1 Disconnecting
! WARNING!
Danger of fatal injury due to high voltage and high pressure!
A qualified electrician is required to disconnect the machine from the mains
power supply.
Switch off the mains power supply before disconnecting the machine, and
secure against switching on.
Make sure power lines have zero potential before disconnecting.

Make sure media lines have zero pressure before disconnecting.
Procedure:
1. Bring clamping unit on transport position (see also transport sketch). Open moving mold
fixing platen.
2. Switch off motor
3. Block media pipings and check them for pressure freedom!
4. Disconnect cooling water
5. Blow out cooling circuits with compressed air
 Open all the flow control devices
 Open the cooling water valve
 Purge the cooling circuit with compressed air.
6. Disconnect compressed air
7. Switch off main switch
8. At the machine drain the used oil from the tank in a reservoir suitable for this purpose or
pump it into it.
9. Switch off and disconnect the power supply for the plant.
Information
It is very important to blow out the cooling circuits and drive motor cooling properly when the
weather is cold. Danger of frost damage!

Disassembly
2 Removal of the machine
! WARNING!
Skilled staff, who are familiar with machine transportation tasks, are required
to transport the machine.
 Use lifting gear and cables with sufficient load-bearing capacity. For weight refer to type
plate on machine or to Plans and Protocols chapter (technical data, foundation plan).
 Only use the marked lifting eyes for transportation. [See Transportation on page 38.]
 The injection molding machine must be lifted and transported in a horizontal position
(side- and lengthwise). Adjust the lifting gear length accordingly.
 Make sure the cables are of sufficient length (taking the maximum spread of the cables
on the crane hooks into consideration 60°).
 Before lifting the machine, check the routing of the cables from the lifting eyes to the lift-
ing gear.
139
Disassembly
3 Disposal
NOTICE!
Environmental hazard!
Used oil and certain machine components can endanger the water supply, and
cause major environmental damage in case of improper disposal!
All machine components and parts are subject to special collection and waste disposal regu-
lations.
Make sure you observe national waste disposal regulations!

Spare parts
Spare parts
Spare parts drawings and lists are included with the printed instruction manual and in PDF for-
mat on the CD.
1 Spare part drawings
141
Spare parts
2 List of spare parts
NOTICE!
Danger of damage to equipment!
The following spare parts drawings and lists are intended solely for the pur-
pose of ordering replacement parts.
Never use them as instructions for maintenance and repair work.

Plans and Protocols
Plans and Protocols
1. Technical data
2. Foundation plans
3. Mold mounting dimensions
4. Hydraulics schematic
5. Circuit diagram
6. Certificates
7. Pressure accumulator test certificate
143
Plans and Protocols

Plans and Protocols
1 Technical data
The technical data are also provided in PDF format on the CD.
145
Plans and Protocols
2 Foundation plans
The base plan is also provided in PDF format on the CD.

Plans and Protocols
3 Mold mounting dimensions

The mold mounting dimensions are also provided in PDF format on the CD.
147
Plans and Protocols
4 Hydraulics schematic
The hydraulics schematic is available in control cabinet and provided in PDF format on the CD.
! DANGER!
Before opening the control cabinet, switch off at main switch and secure
against switching on.

Plans and Protocols
149
Plans and Protocols
5 Circuit diagram
The circuit diagram is available in control cabinet and provided in PDF format on the CD.
! DANGER!
Maintenance work and repairs to the machine's electrical equipment must be
performed by trained and skilled electricians.
Before opening the control cabinet, switch off at main switch and secure
against switching on.
NOTICE!
Use fuses that comply with the specifications in the circuit diagram!

Plans and Protocols
151
Plans and Protocols
6 Certificates
Protocols and certificates are located in the instruction manual only.
6.1 EC declaration of conformity
6.2 Declaration of incorporation

Plans and Protocols
153
Plans and Protocols
7 Pressure accumulator test certificate

Plans and Protocols
155
Plans and Protocols

Additional equipment
If vendor documentation is required due to a special version or special equipment on the injec-
tion molding machine, a description will follow in this chapter!
157

Index
Index EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . . . .24
F
Fixed gate clamping unit and injection unit . . . . . . . . . . . .97
Fixed gate for delivery chute . . . . . . . . . . . . . . . . . . . . . .97
Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Symbols
*Check high-pressure filter . . . . . . . . . . . . . . . . . . . . . . . 113 H
*Check oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
*Check return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Hours of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
*Clamping unit safety gate open . . . . . . . . . . . . . . . . . . . 24 Hydraulic oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
*Clamping unit safety gate x defective . . . . . . . . . . . . . . . 94 Hydraulic oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 107
*EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic oil overview . . . . . . . . . . . . . . . . . . . . . . . . . . .107
*Hydraulic closing safety cartridge defective . . . . . . . . . . 95 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
*Hydraulic closing safety defective . . . . . . . . . . . . . . . . . . 94 Hydraulics schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .148
*Maintenance interval x . . . . . . . . . . . . . . . . . . . . . . . . . . 83
*No oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 L
*No oil temperature change . . . . . . . . . . . . . . . . . . . . . . 112
Leveling the injection molding machine . . . . . . . . . . . . . .40
*Nozzle safety gate defective . . . . . . . . . . . . . . . . . . . . . . 97
List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
*Nozzle safety gate open . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lubricant Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
*Oil filtration active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .99
*Oil level too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
*Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . 111
*Oil temperature too low for automatic mode . . . . . . . . . 111
M
*Tank shut-off valve(s) closed . . . . . . . . . . . . . . . . . . . . 104 Machine overview Victory . . . . . . . . . . . . . . . . . . . . . . . . .11
Maintenance EMERGENCY STOP buttons . . . . . . . . . . .91
A Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Access aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mold anti-twist safeguard (rotational centering) . . . . . . . .64
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mold mounting dimensions . . . . . . . . . . . . . . . . . . . . . . .147
Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Air filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Mount mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Air filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Attaching mold to crane . . . . . . . . . . . . . . . . . . . . . . . . . . 60
N
Noise emission report . . . . . . . . . . . . . . . . . . . . . . . . . . .152
B Not CE-compliant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Nozzle safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Base plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
O
C Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Centering of mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Oil preheating - cooling . . . . . . . . . . . . . . . . . . . . . . . . . .110
Centering the nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Changing a screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
P
Changing from zinc-based to non zinc-based oil . . . . . . 109 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Changing the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Plans and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Check machine - EVER-Q . . . . . . . . . . . . . . . . . . . . . . . . 86 Pressure accumulator test certificate . . . . . . . . . . . . . . .154
Checking the coaxiality of the two mold halves . . . . . . . . 70 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Cleaning after installation . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cleaning of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 R
Cleaning the control panel on the ENGEL control unit . . . 88 Removal of the machine . . . . . . . . . . . . . . . . . . . . . . . . .139
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Compressed air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Replacing a nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Correct mounting of molds . . . . . . . . . . . . . . . . . . . . . . . . 65 Residual dust content . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Residual oil content . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
D Residual water content . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Danger of damage to hydraulic equipment. . . . . . . . . . . 109
Declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . 152 S
Defragmenting the flash card . . . . . . . . . . . . . . . . . . . . . 122 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Safety conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Disconnecting cooling water . . . . . . . . . . . . . . . . . . . . . 138 Safety equipment functions . . . . . . . . . . . . . . . . . . . . . . .24
Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . 140 Safety-conformity of total system . . . . . . . . . . . . . . . . . . .33
Setting up for injection . . . . . . . . . . . . . . . . . . . . . . . . . . .51
E Setting up the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . 152 Software update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Software Update for Version 1.12.xx or newer . . . . . . . .124
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Spare part drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Special safety equipment . . . . . . . . . . . . . . . . . . . . . . . . .26
159
Index
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Starting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
System flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
T
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Transportation notes . . . . . . . . . . . . . . . . . . . . . . . . 38, 139
Transportation sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
V
Vent hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . .108
VirtMould Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

162
ENGEL Austria GmbH | 4311 Schwertberg | tel: +43 (0)50 620 0 fax: +43 (0)50 620 3609
e-mail: service@engel.at | www.engelglobal.com

Engel Service Manual - Machine: Serial No.: 167521 VC 750/150 TECH

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Engel Service Manual - Machine: Serial No.: 167521 VC 750/150 TECH

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VC 750/150 TECH

Serial No.: 167521

Service Manual - Machine

ENGEL AUSTRIA GmbH

Person responsible for documentation: Harald Pichler

Printing date: 14.4.2021

Translation of original instruction manual

Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Setting up for injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Plans and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

2 Service Manual - Machine | Version G/11/30/6/9

Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

4 Service Manual - Machine | Version G/11/30/6/9

The documentation for the injection molding machine contains:

Service manual (Commissioning, Maintenance, Spares)

Operator manual (Operations)

Technical manual (Troubleshooting)

The documentation is available in the following formats:

ENGEL reserves the right to update the documentation.

Information on additional equipment is located in the chapter Additional Equipment.

1.1 Applicable European standards and regulations

98/37 EWG Machinery Directive

2006/95/EWG Low Voltage Directive

89/336/EWG EMC Directive for Electromagnetic Compatibility

EN 12100-1 Machine Safety

EN 12100-2 Machine Safety

EN 294 Machine Safety, Safety Distances

EN 201 Safety Information for Injection Molding Machines

EN 418 Machine Safety, EMERGENCY STOP Equipment

EN 60204-1 Machine Safety, Electrical Equipment for Machines

EN 61310-1 Machine Safety, Displays, Marking and Operating

EN 61310-2 Machine Safety, Displays, Marking and Operating

EN 775 Industrial Robot Safety

6 Service Manual - Machine | Version G/11/30/6/9

8 Service Manual - Machine | Version G/11/30/6/9

2.1 Screen layout

3 General information on injection molding

10 Service Manual - Machine | Version G/11/30/6/9

4 Machine overview Victory

[1] Hydraulic oil tank

12 Service Manual - Machine | Version G/11/30/6/9

Never manipulate, disable, or remove safety equipment.

[Siehe Wartung der Sicherheitseinrichtungen auf Seite 326.]

If you notice that safety equipment is defective,:

ENGEL is not liable for operator errors.

Additional safety instructions found throughout this manual must be observed.

14 Service Manual - Machine | Version G/11/30/6/9

16 Service Manual - Machine | Version G/11/30/6/9

Example of labels on VC650/150 POWER

No access for unauthorized persons!

Do not walk or stand here!

No access with cardiac pacemaker or implanted defibrilla-

Working or standing below moving components and

No access for forklift trucks and industrial vehicles!

No chip cards, small metal parts or watches!

18 Service Manual - Machine | Version G/11/30/6/9

Overhead or suspended load

Warning, highly pressurized, molten material!

Read instruction manual!

Use personal protective equipment!

Use face shield!

20 Service Manual - Machine | Version G/11/30/6/9