Operating Manual

BA 457565 E / F3 268232

Extruder-Die Head
Connection
HX 50/90º
XALOY Screenchanger –EM20

Translation of the ORIGINAL OPERATING MANUAL

Manufacturer’s Address

HOSOKAWA ALPINE Aktiengesellschaft

Peter-Dörfler-Str. 13-25
86199 Augsburg
GERMANY

Telephone: +49 821 5906-666 Fax number: +49 821 5906-602

E-mail: plastics@alpine.hosokawa.com
Internet: www.alpinehosokawa.com

04.2015
EBA-HX 50/90º – XALOY EM20 BA 457565 E

Table of Contents Page

1 General Information..................................................... 3
1.1 Introduction ............................................................................................ 3
1.2 Target group .......................................................................................... 3
1.3 Order-specific application ....................................................................... 3

2 Safety............................................................................ 4
2.1 Directives ............................................................................................... 4
2.2 Safety Symbols ...................................................................................... 5
2.3 Regulations for prevention of accidents.................................................. 6
2.4 Safety devices........................................................................................ 8

3 Function and Description

of the Extruder-Die Head Connection ........................ 9
3.1 Principle of operation / design ................................................................ 9
3.2 Working range........................................................................................ 9
3.3 Technical data...................................................................................... 10
3.4 Dimensions / Weight ............................................................................ 11

4 Transport / Connections ........................................... 12

4.1 Transport ............................................................................................. 12
4.2 Connections ......................................................................................... 12
4.2.1 Mounting to the extruder ...................................................................... 12
4.2.2 Mounting to the die head ...................................................................... 12
4.2.3 Electrical connections .......................................................................... 12

5 Operation ................................................................... 13
5.1 Commissioning .................................................................................... 13
5.2 Screen changing procedure ................................................................. 13
5.3 Safe operation...................................................................................... 13

6 Maintenance / Servicing ............................................ 14

6.1 Cleaning ............................................................................................... 15
6.1.1 General information.............................................................................. 15
6.1.2 Parts in contact with the melt ............................................................... 15
6.2 Spare parts .......................................................................................... 16

7 Screw tightening torques .......................................... 17

1 Subassemblies .......................................................... 18
1.1 Extruder-Diehead-Connection Nr.: 457565 .......................................... 18
1.2 Heaterelements 230 V / pluggable Nr.: 457217 .................................... 20

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1 General Information
1.1 Introduction
This operating manual forms an integral component of the technical
documentation for the entire line. Knowledge and observation of this
documentation is a prerequisite for operating the unit.
Always store this operating manual close to the system for quick and easy
reference.
Make sure that it is complete and fully legible.
The operating manual, especially the safety instructions, must be read
and applied by every single person charged with working on or at the
system.

1.2 Target group

This operating manual is directed at persons who:
• possess the requisite qualifications and experience;
• are conversant with the prevailing standards, directives and accident
prevention regulations;
• have been trained and fully understand the function and operating
conditions of the extruder;
• and who are able to recognise and avoid safety hazards.

1.3 Order-specific application

In its function and design, the extruder-die head connection described
here is laid out specifically for the manufacture of blown film made from
polyolefines.
Any other application or the processing of a product other than the one
named above contravenes the order-specific application and is thus
prohibited.
HOSOKAWA ALPINE is not liable if arbitrary changes or modifications are
made to the extruder-die head connection without the prior written
consent of the manufacturer. This applies in particular to modifications
that compromise the safety of the extruder.
HOSOKAWA ALPINE is also not liable if accessories provided by the user
– especially with respect to safety-specific parts – do not conform with the
relevant accident prevention regulations or are not installed properly.
The manufacturer's declaration issued by HOSOKAWA ALPINE becomes
null and void if impermissible modifications are made.
Without special safety measures, it is prohibited to process harmful or
toxic products with the extruder-die head connection. It is prohibited to
install the extruder-die head connection in a potentially explosive
atmosphere.

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2 Safety
2.1 Directives
With regard to design and equipment of the extruder / die head
connection, the relevant directions contained in registers “A” and “B” of
the general administrative regulation concerning the „Gesetz über
technische Arbeitsmittel“ (law on technical working means) have been
adhered to.
The extruder / die head connection conforms to the following directives:
• EC Machinery Directive 2006 / 42 / EC, Annex II Part 1 B
• EN ISO 12100 Basic terminology, methodology,
specifications and risk minimisation
• EN 1114-1 Extruder C standard

The electric system of the extruder / die head connection conforms to the
VDE regulations for processing machinery with nominal voltages up to
1000 V (low voltage standard); VDE 0113 if the extruder/die head
connection was delivered by HOSOKAWA ALPINE AG with complete
electric equipment.

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2.2 Safety Symbols

The following symbols are used throughout this operating manual:

DANGER ! Indicates a dangerous situation where if

the safety regulations are not observed,
can lead to fatal or serious injuries with
permanent disability.

WARNING ! Indicates a dangerous situation where if

the safety regulations are not observed,
can lead to serious injuries.

CAUTION ! Indicates a dangerous situation where if

the safety regulations are not observed,
can lead to minor injuries.

NOTICE ! Indicates a dangerous situation where if

the safety regulations are not observed,
can lead to material damage.

Tips for economic and effective operation.

Pictograph posted on the machine

Hazard caused by hot surfaces

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2.3 Regulations for prevention of accidents

When setting up the extruder / die head connection and its

accessories, the operator must observe the following
recommendations and regulations:
• the recommendations contained in the operating manual of the line,
• the recommendations contained in this operating manual,
• the relevant general regulations for prevention of accidents
• the relevant local regulations for prevention of accidents
• the special directions of the competent trade association

For operation and maintenance, the operator must observe the

following items:
• Only authorized persons may have access to the operating area and
danger zone of the extruder / die head connection. Unauthorized
persons must be refused admittance.
• The line in which the extruder / die head connection is installed may
not be operated without a master switch.
• Only skilled and trained personnel may operate the extruder / die
head connection or perform service and maintenance work.
• Any work at the extruder / die head connection, in particular at the
electric system, may only be performed when the complete line is off
circuit and protected against switching on. Before switching the line
back on, re-install all safety devices.
• The extruder / die head connection may only be opened when the line
is in complete standstill. The same is valid for removal of safety
devices.
• Wear protective gloves when handling heated parts of the
extruder/die head connection and the product (film bubble, melt
cakes): Danger of burns!
• Use appropriate lifting gear. Observe maximum permissible rope
angle.
• Observe instructions for service and maintenance.
• Always keep the operating area clean. Immediately remove resin
granules or spilled gear oil.
• Put hot start-up cakes immediately into appropriate containers.
• When performing work above a height of 90 cm, use appropriate
equipment with safety devices.

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The extruder/die head connection may only be used as directed, i.e.

• As described in section 1.3 (Application of equipment as directed).
• The conditions for operation, service and maintenance
(section 5 and 6) must be kept.
• Arbitrary retrofitting and modification of the extruder/die head
connection are not permitted.

The operator is responsible for performance of the accident prevention

measures according to the official regulations and for observation of the
accident prevention regulations.

The operator is obliged to train the personnel regularly.

Commissioning of the machine is not permitted until the

operator has made sure that
• the machine is assembled and installed properly
• all safety devices are installed and functional
• the entire machine or the line in which it is to be installed
conforms to the CE standards for machines and that the
CE conformity declaration exists, if the machine is used in
one of the countries of the European Community.

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2.4 Safety devices

General information

• All safety devices must be in place and functional anytime.

• Do not modify safety devices or put them out of operation.
• Check the function of safety devices daily.

The following table lists sources of danger at the line together with the
devices for accident prevention.

Source of danger Safety devices

Heater elements Warning sign „hot surface“

Exiting melt • A pressure sensor shuts the

extruder down if the
permissible maximum
pressure is exceeded.
See the section „Technical
Specifications“.
• In addition a burst plug opens
if the pressure exceeds the
maximal mechanical allowed
system pressure. (option)

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3 Function and Description

of the Extruder-Die Head Connection
3.1 Principle of operation / design
This extruder-die head connection serves as a connecting element
between the extruder and the die head in the film blowing process.
It has the following functions:
• Connection subassembly at extruder
• Connection subassembly at die head
• Pressure measurement upstream of screens
• Pressure measurement downstream of screens (option)
• Melt temperature measurement
• Temperature control by means of ceramic heater elements
• Mount and screen changer for the melt filter package

3.2 Working range

The extruder-die head connection is designed for processing:
• all standard polyolefines;
• up to a maximum permissible temperature
(see section “Technical Specifications”);
• up to a maximum permissible melt temperature
(see section “Technical Specifications”);

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3.3 Technical data

Temperature control zones:

Zone S1: 2-point control

electric heating = 1.95 kW

Zone U1: 2-point control

electric heating = 2.00 kW

Zone A1: 2-point control

electric heating = 2.50 kW

• Maximum admission pressure/melt Pmax = 680 bar

• Maximum operating temperature Tmax = 250 ºC

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3.4 Dimensions / Weight

Weight:
Extruder/die head connection complete approx. 120 kg

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4 Transport / Connections
4.1 Transport
• Transport by crane
Suspend the extruder/die head connection by means of rope slings.

4.2 Connections
4.2.1 Mounting to the extruder
• Align the extruder/die head connection towards the extruder.
• Make sure that a distance of least 2 mm is kept between the screwed
flange and the extruder/die head connection.
• Fasten the extruder/die head connection by means of the provided
socket head cap screws observing the specified torque.

4.2.2 Mounting to the die head

• Roughly align the complete extruder with the frame in the direction of
the extrusion axis.
• Push the extruder home carefully on the sealing surface until it abuts
the die head connection.
• Make sure that the sealing surfaces sit plane and centric by adjusting
the extruder height alignment unit or by lateral alignment of the
extruder.

To check the alignment of the sealing surfaces, insert a

sheet of paper between them. It must be evenly pressed
over the entire sealing surfaces.

• Screw up the flanged joint with the specified torques.

4.2.3 Electrical connections

Connect the temperature controllers and the heater bands according to
the instructions in the manual of the line.

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5 Operation
5.1 Commissioning
The extruder/die head connection can only be initiated together with the
complete line.
refer to instruction manual for the line, section “Commissioning”.

5.2 Screen changing procedure

refer to separate instruction manuals by Xaloy Ltd.

NOTICE !
If the extruder needs to be re-heated, it is essential that a
melt pressure of approx. 200 bar is built up in front of the
screen – at least briefly – before the first screen change!
This is the only way to ensure that the screen pack abuts
the screen support snugly. Otherwise, the screen pack can
get stuck in the gap and block the swivel movement.

5.3 Safe operation

• Control of the heater elements
Check whether the heater elements sit close before and after heating-
up and re-tighten evenly, if necessary. (The heat can only be transfer-
red safely to the part to be heated if the heater element sits close
against it. Otherwise there is danger of local overheating and burning
out of the heater wire).

• Screen change
We recommend using a pressure measuring device (optional) before
the screen changer, because the degree of contamination of the
screen becomes obvious from the increase in pressure. The screen
changing intervals should be adjusted accordingly. If you do not use a
pressure measuring device, the screens must be changed at regular
(and rather short) intervals. Melt pressure may not exceed 680 bar.
• Tightening of leaks
Leaky screw connections must always be tightened in pressureless
condition. The torque must never exceed the specified value. In case
the connection remains leaky, the parts must be dismounted and their
sealing surfaces must be cleaned carefully of melt residues.
Subsequently check the sealing surfaces for damage and re-assemble.

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6 Maintenance / Servicing
Maintenance to the extruder-die head connection is essentially limited to:
• Functional check as described in the section "Operation".
• In the event that rupture discs are installed as additional pressure
monitoring devices, these should be exchanged once a year because
high operating pressures, high temperatures and especially
alternating and heavy loads can considerably reduce their service life.

The following points should be checked regularly:

• Are all heater bands seated flush?
• Are all heater bands intact?
• Are all control zones functioning correctly?
• Does the melt pressure control function?

Subsequent to assembly procedures

• Were all screws tightened to the correct torque?
• Visual check for wear.
• Cleaning procedures.

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6.1 Cleaning
6.1.1 General information
Dirt and resin residues in the extruder can adversely affect its operating
reliability.
We advise cleaning the entire extrusion line during the course of
maintenance procedures.

6.1.2 Parts in contact with the melt

The cleaning intervals of the melt-contact parts are dependent on the type
of resin and the masterbatch, etc.
To facilitate cleaning, it is good policy to heat the extruder to the
processing temperature of the material last processed or to keep the
extruder at this temperature. Remove the parts to be cleaned one by one
and clean them immediately before they cool down.
Heating to a temperature in excess of 300 ºC or sudden cooling will lead
to cracks, distortion and destruction of the surfaces.
• Never use hard or pointed tools
• Avoid using any force
• Clean all contact and seating surfaces carefully
• Deposit cleaned parts on felt or cardboard only

Once the surfaces in contact with the melt have been cleaned, polish them
with the supplied polishing paste and then spray a thin coat of silicon oil
onto the surfaces.
Prior to assembly, apply a thin coat of the heat-resistant lubricating paste
supplied with the tools to all bolted connections.

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6.2 Spare parts

Please specify when ordering spare parts:
• Order number and system/line number
(see nameplate on extruder and/or system operating manual)
• Machine type as per nameplate
• Number of the operating manual
• Subassembly parts number
• Position number
• ID number (if quoted)
• Designation (see spare parts list)
• Electric parts:
the subassembly or components list in which the part is listed.
(List located either in control cabinet or see the circuit diagram.)
• Quantity of parts required

Additional information for electric components:

• Voltage and frequency

In the case of screws, make sure that the strength class indicated on the
screw head – e.g. 8.8 or 12.9 – is in agreement with that of the original
screw.
We recommend keeping a stock of the most common spare parts. A
corresponding list is available from HOSOKAWA ALPINE upon request.

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7 Screw tightening torques

Unless otherwise indicated on the component, the following HOSOKAWA
ALPINE standard torque values apply under the condition that the screws
are:
• equipped with HOSOKAWA ALPINE washers
• in cold condition
lubricated with heat-resistant lubricating paste.

Screw size Strength 8.8 / Nm Strength 12.9 / Nm

M 16 5 9

M 18 12 22

M 10 24 40

M 12 40 70

M 16 100 170

M 20 200 340

M 24 350 600

M 30 700 1200

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1 Subassemblies
1.1 Extruder-Diehead-Connection Nr.: 457565

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Extruder diehead connection No.: 457565

Pos. No. Designation german Designation Qt. dwg/Norm Materi

al
10 442231 SIEBWECH. XALOY XEM20 Screen changer 1 442231
ED50
50 415336 GEWINDEFLANSCH HX50 Screwed flange 1 244854 1.7225
M80x3 V-CR
51 190700 ZYL.SCHRAUBE M 20X 40 Socket-head cap screw 6 ISO 4762 8.8
(912)
60 412305 UMLENKSTÜ. Deflection piece 1 412306 1.7225
D28x90°+1/2"UNF V/CR
61 104902 ZYL.SCHRAUBE M 16X120 Socket-head cap screw 4 ISO 4762 8.8
(912)
62 077802 UNTERLEGSCHEIBE - M 16 Shim 4 184931 1.2344

70 365764 ANSCHL.BU D28X180 Connector 1 365764 1.7225/

M56/M80 CR
80 382862 GEWINDEFLANSCH M80X2 Screwed flange 1 382862 1.7225
V-CR
90 382714 GEWINDEFLANSCH M80X2 Flange 1 382714 1.7225
V
100 446907 ÜBERGANGSSTÜCKE Ø28- Set of heater elements 1
20MM
110 165316 ZYL.SCHRAUBE M 16X 55 Socket-head cap screw 4 ISO 4762 8.8
(912)
111 077802 UNTERLEGSCHEIBE - M 16 Shim 4 184931 1.2344

120 040350 VERSCHLUSSCHRB. Screw plug 1 040350 1.4571

1/2"20UNF-40LG
121 116432 VERSCHLUSSCHRB. Screw plug 1 116432 1.4571
1/2"20UNF-80LG
200 276490 ERSATZSIEBPAKET D 52,39 Sparepackage screens 10
4-LAG
250 414566 STÜTZE SWA2011 90°(+-X) Support 1 414566
R/L
300 457566 HEIZELEMENTE HX50 Heater elements 1
90°XEM20
330 286473 MASSETEMP.MESSFUEHLER Melt temperature sensor 1 212653
12/114LG
340 443953 DRUCKAUFNEHMER SW Melt pressure sensor 1

350 441571 BERSTSCHR GRD-12500-102- Burst plug 1

W

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1.2 Heaterelements 230 V / pluggable Nr.: 457217

Sensor
Zone S1

Sensor
Zone U1

Sensor
Zone A1

Zone Pos Nr Dimension Power [W]

S1 10 1 Ø 210 1× 136 1 200 W
15 1 Ø 203 1× 28 600 W
16 1 Ø 203 1× 136 1 600 W
U1 20 1 Ø 210 1× 111 2 000 W
A1 30 1 Ø 280 1× 166 1 500 W
40 1 Ø 160 1× 166 1 000 W
50 1 Ø 280 1× 166 1 500 W
51 1 Ø 280 1× 171 1 750 W

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Heater elements No.: 457217

Pos. No. Designation german Designation Qt. dwg/Norm Materi

al
10 121236 ZYL.HEIZKPR. D210XL 36 Cylindrical heater 1 WN ZHK-6 KERA
1200W element MIK
15 423764 ZYL.HEIZKPR. D203X 28,5 600 Cylindrical heater 1 423764 KERA
W element MIK
16 326584 ZYL.HEIZKPR. D203XL 36 600 Cylindrical heater 1 326584 KERA
W element MIK
20 268460 ZYL.HEIZKPR. D210XL111 Cylindrical heater 1 268460 KERA
2000W element MIK
21 006737 SCHLAUCHKL.HY-GEAR D Hose clip 2 WN 2-9701 1.4310
51-254
30 238414 ZYL.HEIZKPR. D80 X 66 Cylindrical heater 1 238414 KERA
500W element MIK
40 404298 ZYL.HEIZKPR. D160 X 66 Cylindrical heater 1 404298 KERA
1000W element MIK
50 396363 ZYL.HEIZKPR. D80 X 66 Cylindrical heater 1 396363 KERA
500W element MIK
51 404293 ZYL.HEIZKPR. D80 X 171 Cylindrical heater 1 396363 KERA
750W element MIK
100 020894 ADAPTER 40 LG. TYP ET-19S- Adapter 3 ST-VZ
1011
200 414095 HEISSGERAETE- Power socket 2 VOLLG
STECKDOSE T155SI UMMI

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