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QUALITY CERTIFICATE MACHINE |Plastic Injection) MACHINE NAME |Mold Machine MODEL PL2000/700 MACHINE MANUFACTURING SERIAL \yo/-Joz~17123 — NUMBER THE MACHINE IS QUALIFIED FOR SALE. ] QUALITY INSPECTOR MANAGER cao ACCESSORIES PRECISION TEST REPORTPL2000 4 TIANJIAN PLASTICS MACHINERY MAQUINA DE MOLDAGEM POR INJECAO Manual de Instrucao NINGBO HAITIAN HUAYUAN MACHINERY CO., LTD. CH) cae ISOQOO1A UE “"NO.697A007 —{) i2Forward Customer Service- Telephone Number n = 86-574-86177242/86181886 itr Central Exchange FAX 86-574-86221864 Sales es 86-574-86177242/86181886 Department FAX 86-574-86221864 Spare Parts Sales| @ 86-574-86182613 Center FAX 86-574-86182662 After Sale Service | @& 86-574-86182615 Department FAX 86-574-86182662 .“y 86-574-86181685 Technical Service See close Customer's Complaints | @ 86-574-86182628 Service FAX 86-574-86221864 315801 Ina spirit of continuous improvement, HAITIAN welcomes your suggestions. Please contact us timely with no hesitation if you have any questions or requests. © _ Ningbo Export Process Zone, Ningbo, Zhejiang, China » 29H OQa9 © weconensonanTIANJIAN PLASTICS MACHIN Forward FOREWORD General notes on the operating manual Prerequisite for perfect machine operation is knowledge of how the individual units function, the handling and maintenance of the machine. In this respect this operating manual is a useful aid. It informs your on the correct usage of your HT injection molding machine and belongs therefore, in the hands of every responsible machine-setters. Before putting your machine into operation, please study this operating manual thoroughly. Pay particular attention to any text preceded by the symbol, This also contains advice with regard to your safety. CF no : “pay special attention A Attention: -safety information This machine is in accordance with the standard available for “JB/T7276-plastic injection molding machine’ The description and diagrams given in the operating manual are in ine with the production range. We stress that this is subject to alteration according to special requests or further technical developments. Reprinting and duplication, including extracts, requires ours authorization. The handing of this manual to a third party is not permitted. BQ QLD O mensncmTIANJIAN ICS MACHINER) _ Table of contents -Manual 1 MANUAL1 Chapter 1 Installation and Alignment, 4-1 1.4 Cable suspension diagram ......nmnnnnnmnnnnnn 14 1.4.1. Mini- type machine lifting ...... sevens VA 4.1.2 Middle type machine lifting secetscneenenee 44 4.4.3) Unloading... coe 13 1.1.4. Aids for machine transportation 4-4 1.1.5 Removal of protective evceesee 14 1.2. Environment Requirements for Installation... . 1-4 4.3. Machine dimensions & Foundation plan. — 15 1.4 Installation and Alignment 15 1.4.4 Installation ..ccccccseeenennsnenennnennenee 15 1.4.2. Alignment....... - sesseeittnteneteaetiseensessee 16 4.5 Water cooling system... 1-10 4.5.1 Water cooling system layout. etna 410 1.5.2. Discharge of cooling water........ 111 1.5.3 Flow rate of cooling water...... 111 1.6 Filling with Hydraulic Oil i seseeeseee 112 1.7. Power supply oe vo 112 1.7.4. Check rotating direction of pump motor seveeneene 113 1.8 Adjustable mounts . 1-44 Chapter 2 Safety 2-1 2.1. General safety regulations so - 24 2.1.1 Machine main safety scutcheon ........ seceesevnee 2A 2.1.2 Maintenance & repair Work... 29 2.1.3. Toxic fumes sacnsneaneeanaassnenansnveecees 2-10 244 Explosive decomposition sessesiseeeee 210) 2.1.8 Prevent accidents caused by exceeding charge 2-10 2.2 Safety equipment... 2 2.2.1. General equipment. 211 2.2.2 Safety equipment eoceesnteee 21 2.2.3 Moveable guarding in the mould area .... soos 212 2.2.4 Nozzle guarding wc. sree . 212 2.2.8 Fixed guarding.......... srintcenenate 218 22.6 Other dangers when the nozzle guarding is open 213 23 Hydraulic safety equipment oo 2.13 24 — Electrical safety equipment... 214 25 Checking the safety equipment.......... a 214 © wecratvanaseTIANJIAN PLASTICS MACHINERY Table of contents -Manual 1 Chapter3 Putting into operation we 3-1 3.1. Preparatory work . 34 3.1.1 Correct clothing .. 34 3.1.2 Necessary jobs before testing the new machine ....ceco. 3-4 3.2 Testing and adjusting the new machine. seneesesetteees Se 3.2.1 Power on. ee soe 34 3.2.2 Start running electric motor...... . 32 3.2.3. Start heating system... 3-2 3.2.4 To operate the machine manually - 3-2 3.2.5. Semi-automatic & full automatic operation of the machine... 3-2 3.3 Procedures of mound installation 33 3.3.1. Preparation essen pene BB 3.3.2. Procedures of mound installation . 34 3.4 Procedure of the plastic injection coceencteenetnneenes 4B 3.4.1 Notes before the plastic injection a 2 38 3.4.2 Temperature of the hydraulic oil eecesetsetestnseatseee, 6B 3.4.3 Procedure of the plastic injection socsseenenentes BF 3.5 To stop the plastic injection. 38 3.5.1. To stop injection before completion of molding or before a temporary termination............ 38 3.5.2 To stop injection at finishing of material or completion of workpieces or at necessity to turn off the power 3-8 3.6 To remove the mould age 3-8 3.7 To remove the screw and the heating barrel, 3.9 3.7.1 Before removal ....sccsssntneenn 3-10 3.7.2 To move the plastic injection unit aside 3-10 3.7.3 Removal of related parts............s.ccescseseee 3-11 3.7.4 Removing the screw... seen 342 3.7.5 Removing the Screw Tip ....sscsssecee seeeseseessenessee, S13 3.7.6 Removing the heating barrel : 3-14 3.7.7 Removing heating cylinder—method 2 3-14 3.8 To discharge air from the proportional valve.. svseensenee 315 Chapter4 Maintenance 41 4.1 Maintenance plan. . . 44 4.2. Lubrication and Hydrauli¢ off. 42 4.3 Lubrication and maintenance j..........0006 4-3 4.3.1. Composition and characteristic of lubrication system 43 4.3.2 Requirements of lubrication Oil 2.0.0... 43 4.3.3. Principle of lubrication . 43 DO mecrneonnaseTIANJIAN ASTIC 434 44 45 4.5.1 45.2 45.3 45.4 45.5 45.6 46 4.6.1 462 4.6.3 46.4 46.5 47 48 49 494 4.9.2 4.93 4.10 4. Appendix 1 Appendix 2 ACHINERY _.. Table of contents -Manual 4 Maintenance of lubrication system 44 Routine check. oe . 48 Heat exchanger(oil cooler) Construction of cooler Put into operation Check-up, maintenance, clean of cooler Cooler decompose and assemble... Sealing performance test Fault and elimination Filter Dismantle Cleaning Installation Note. nage Change hydraulic oil Air filter Check hose circuit : pene Cleaning and checking of screw and heating barrel Cleaning and checking screw......... Cleaning and check the heating cylinder... ‘Screw and heating barrel installation. Moving platen sliding foot adjustment . so ‘Temperature setting chart of plastic and barrel... 222 QP Q weesTIANJIAN PLASTICS MACHINERY Table of contents -Manual 1 MANUAL2 ChapterS — Technical Parameters & Machine Outline 5-4 Chapter6 Mechanism.......... . = 6-1 Chapter7 —_ Hydraulic......... 741 Chapter8 — Electric Unit......00000000........ 8-1 Chapter9 Controller operation......... wee 1 Aueroerot tian 4 2 QQ QQ QM mrcaernenan,$ TIA NJIAN Chaptert installation and Alignment ERY Chapter’ installation and Alignment _ 1. 1Cable suspension diagram Note: Moving piaten should located in such position that the mold height is down to its min before lifting 1.1.1. Mini-type machine lifting(whole frame) I ml | 1.1.2 Middle-type machine lifting(combined frame) Middle-type machine are designed as combined frame and unable to lifting the whole frame. Disconnect the frame into injection unit and clamping unit and lifting them individual. Procedure of disconnecting and lifting can be found in next pages description. Frame of middle-type machine connecting indication The ‘asia clamping uit lac injection uit 4-4@ TIANJIAN PLASTICS MACHINERY Chapter Installation and Alignment Note: Please refer the settings of auxiliary equipment required for machine delivery to chapter 1.1.4. 1.1.2.1 Procedure of disconnecting and connecting the machine frame. 1)Disconnect 1) Dismantle the carriage cylinder base and disconnect it for fixed platen (2) Unscrew the locking bolt on top cover, dismantle top cover smoothly. (3) Unscrew the locking bolt on side cover, dismantle side cover smoothly, }) Release the locking nut in frame of injection unit from the top down. }) Remove cylinder locating pin ) Tighten the cable loop as be found in chapter 1.1.2.3. And drug it level to apart from the clamping unit. (4 © 6 2)Connect (1) Place the adjustable mounts::near the foundation bolt hole on eligible foundation. (2) Positioning the clamping unit first according to indication of suspension diagram in chapter 1.1.2.2 and 1.1.2.3. Then suspect the injection unit to corresponding position and smoothly placed. Pay attention to the position of link bolt and corresponding hole. Move the bolt to enter the hole, then install spring washer and locking nut, after locking elementary, install the cylinder pin. (3) Tighten the locking nut after level adjustment. (4) Install the top cover and side cover, 1.1.2.2 Middle-type machine suspension—clamping unit £9 22 BR QO wows 1-2@» TIANJIAN PLASTICS MAC Chapter Installation and Alignment 1.1.2.3 Middle-type machine suspension—injection unit yy fl N A. 4.1.3 Unloading When the injection molding machine had been delivered remove all packing. Check weather the machine is undamaged and in good condition Written acknowledgement of any damage in transit must be made by the carrier, and the manufacturer must be notified immediately so that a claim be made on the transport insurance _ Accrane with sufficient lifting power is request for off-loading. Machine weights (see » chap6.1) To protect the machine the cables under tension should not be attached to the weaker parts of the machine. The machine should be moved according to the information given in the cable suspension diagram (chap1.1) and using the aids shown in chap 1.1.4 Should the machine need to be moved again in the factory and no crane is available, transport should be carried out with the aids of rollers. Note: Point 1: cranes and carriers of sufficient power capability should be used (including the cranes, lifting equipment, hook, and steel cable etc.) Point 2: In case that any hoisting steel cable has direct contact with spare parts of machine, we should place layers of rags between the steel cable and spare parts so as to avoid any damage of machine's spare parts, for example, pulling shaft of plastic 1-3TIANJIAN HINERY Chapter1 Installation and Alignment injection machine etc. 7 Point 3: Pay attention to the stability and level status of the machine during being lifted up Point 4: Until the unloading and moving are completely done, the wood and other layers or cushions undemeath the machine can be removed Note: re CF The manufacturer accepts no responsibility for any damage which occurs in transit 1.1.4 Aids for machine transportation Name [Quantity | ~__ Remark [Cable and Hooks _ _ _| 2 Protection for the clampin: Tal |transit. or the clamp! @ unt | 1 | Delivered with machine Protection for Injection unit transit_| 4 [Delivered with machine Rolling Timber or Roller For| Atleast 3 Moving the Machine on the “'OEE!° | Length near the width of frame Ground a Woods, rags | Some 1.1.5 Removal of protective All exposed machine parts such as piston rods, tie bar, and platen areas are treated with an anti-corrosive agent prior to delivery of the machine. This creates a fine protective film which can combine with the lubricants on the bearing surfaces and with the hydraulic oil without any problem Attention: Please don't remove any antirust on the part that has direct contact with machine operating system. This provides basic protection against rusting and hostile environment for machines. Except in case of necessity, wipe off the antirust with cloth during operation. Attention: DO NOT use chemical solvent to wipe off the antirust. 4.2 Environment Requirements for Installation During the installation of this machine, please do confirm whether environment requirements listed in this section have been met fully or not. If the requirements are not met, the machine will not be able to exert its complete performance and will even possibly engender wrong operations, which might cause damage and lead to decrease the operation life of the machine. » Temperature: 0~40 ‘C (Environment temperature during the machine's 1-4& TIANJIAN _Chapter Installation and Alignment ~ operation) » Humidity: 75% below (comparative humidity), no dewfalls. » Altitude: below 1000 meters. A Attention! When the humidity is too high, it will affect the insulation or speed up the aging of the spare parts. Although no special measures to decrease humidity is suggested, it is still preferable not to place the machine in a humid place. Don't install the machine in places that has much dust, organic gas, or erosive air. Try to place the machine faraway from the places that might have electric interference or machines that has magnetic field (for example, welding machine etc) 1.3. Machine outline and foundation plan —Refer to machine outline & foundation plan (chap§) during the installation. 1.4 Installation and Alignment 1.4.1. Installation Proof of sufficient load bearing capacity can only be given by an expert (structure engineer) In case that machine is installed on the reinforced concrete ground, there is no additional preparation for groundwork needed before installation. In case that machine is installed on common workshop ground, then groundwork is needed prior to installation. The maximum surface pressure that the machine has on its support concrete groundwork can be calculated through machine's weight and adjustable mounts number and area. Foundation bolts should be used in fixing the machine (large or middle type machine) _ to the ground surface or groundwork cS Note: Plastic Injection Machine can be placed on soft adjustable anti-vibration mounts which means a lot of work in preparing the groundwork need not apply. How to use adjustable mounts should be found in chapter1.6.(adjustable machine and the ground, which redytes ae (uly te pressure that machine has on the ground. You must make sure Wat 4B grélifid Hasenough capacity to bear the remaining load Note: 2 2 2 9 wemenun 1-5TIANJIAN cS MACHINERY Chaptert Installation and Alignment After the machine is being fixed at the assigned place, all the delivery protection materials must be taken away. These protection and safety materials should be kept in good conditions so that they can be used again if necessary in the future. The constituent parts such as hopper, which has been disassembled from the machine during the delivery, should be put back on the machine. 1.4.2 Alignment 1.4.2.1 Alignment items The machine is completely aligned prior to delivery. This applies specifically to 1) Parallelism of mold platens Generally, the measures descried below are sufficient to align the machine bed. If tolerance exceeds maximum permissible levels, please inform the manufacturer. Tolerance of platen parallelism Space between tie bar| Tolerance when Tolerance when available clamping force is zero__| clamping force is max 200-250 0.20 0.10 250--400 0.24 0.12 400-630 0.32 { 0.16 630-1000 0.40 0.20 1000-1600 0.48 0.24 71600--2500. I 0.64 0.32 2) Nozzle centering ‘Axiality between nozzle and mould orientation hole can be adjusted as follow plan. It should reach the follow claim about axiality after centering. Mold orientation hole diameter_| ©80~100 © 125~250 above ®315 Axiality 0.25 <0.30 S0.40 Adjusting plan: (1)Adjusting landscape and vertical level of machine body which between the two mold platens (2) Unscrew the fasten screw and locking screw (see chapter3.3.2 diagram1,2) (3)As right diagram indication, measure h1, h2, h3, h4 by vernier caliper with 0.05mm acouracy. Adjusting it to make h1=h3, h2=h4 Tolerance of adjusting must accord with the request of the above chart. Meanwhile, Fixed platen Diagram (1) adjusting it to make 5 1= 6 3, 6 2= 5 4 (see diagram (2). Finally, by using level meter to check about the levelness of screw guide bar, it is suggested that the parameter 2 © weemenvetan 16@ TIANJIAN LASTICS MAC Chapter‘ Installation and Alignment shall be around 0.5mm/m (see diagram (3)), After adjustment, the fastening bolts and lock nuts shall be screwed down, 3) Adjusting landscape and vertical level of machine body which between the two mold platens. The detail adjustment of landscape and vertical level of large and middle type machine body can be found in chapter 1.4.2.2 Min. mould neat peiton Movable patn Level | ‘adistztle mounts Fmd platen Moi platen asst permissible ‘user Boctevel meter ~ N = Agist bot and ocknut in horantal drection Adj toe nace as iageam (2) 1.4.2.2 Machine alignment The moving platen have a high weight and high moving intertia, so it is essential to ~adjust the machine body's guide carefully to ensure the smoothness when it moves on the guide. 1,4.2.2.1 Aligning the guide level of mini-type machine. 17TIANJIAN PLASTICS MACH Chapter1 Installation and Alignment Min. mould heh pein, Fined platen Aduarbod and eke \_ eric es Small machine foundation adjustment diagram 1) Ensure the distance between the fixed platen and moving platen is minimum, install adjustable mounts, generally about 6 or 12 pieces, in accordance with installation hole 2) Place a level meter (m) in landscape direction on the machine track between the mold platens as illustrated above (close to the movable platen as much as possible) 3) Initial aligning: adjusting adjustable mounts to make the air bubble in the middle of level meter. This is for four sides. (The adjustment method of adjustable mounts can be found in chaptert.8.) 4) Fine aligning: repeat the step 3) for several times until the landscape level around 0.5mm/m and vertical level around 0.5mmi/m. 5) Level alignment in accordance with requirements on the machine can be only confirmed by using below 7Mpa working pressure to start mould height adjusting motor smoothly and below 3Mpa working pressure to operate carriage cylinder steadily. 1.4.2.2.2 Aligning the guide level of large and middle type machine 1) Before installation, clean the foundation surface, place adjustable mounts as chapter 5 foundation plan. Lifting the units leaving the surface about 500mm, mounting foundation bolt, flat washer, spring washer, and nut from the bottom up. Screw nut to enable bolt end plane above 3 pitches to the up plane of nut 2) Place the machine on mounts. Pay attention to align the foundation bolt with the reserved mounting hole. Connect the injection unit and clamping unit together as chapter1.1.2.1 indication, and then carry out initial level adjustment as per adjusting procedure 3. 3) After level is confirmed by level meter, pour concrete into the prepared mounting 22 QQ QO wennmsanate 1-8TIANJIAN PLASTICS MACHINERY Chapter1 Installation and Alignment hole and fasten foundation bolt. 4) After a period of maintenance and ensure the cement set hard (about 10 days in ‘summer and about 15 days in winter), fine adjusting level of machine body shall be carried out. Fasten the foundation bolt to fix machine by means of tooling bar after measurement by level meter. Length of tooling bar [ Bolt model Length of tooling bar ] ue | 550 | | Mie - 600 _ M20 700 l _M24 at 850 Base box Mjsimum di Moving platen Quench puide Adjustable mounts el Middle and large type machine foundation plan Adjusting procedure 1)Ensure the distance between the fixed platen and moving platen minimum 2)Place the level meter on quench guide of the machine operating side. Level meter placed as near as the moving platen between the fixed and moving platen as diagram indication. 3) Initial aligning: adjusting adjustable mounts to make the air bladder in the middle of level meter. This is for four sides. (Adjustment of adjustable mounts can be found in chapter1.8) 4) Fine aligning: repeat the step 3) for several times until the horizontal level around 0.5mm/m and vertical level around 0.5mm/m. 5) Aligning machine frame beneath the injection unit based upon the center of nozzle and fixed platen, tolerance must accord with the request of chapter1.4.2.1 6) Level alignment in accordance with requirements on the machine can be only 2 QO wecnnsineten 19TIANJIAN PLASTICS MACHINERY Chapter1 Installation and Alignment confirmed by using below 7Mpa working pressure to start mould height adjusting motor smoothly and below 3Mpa working pressure to operate carriage cylinder steadily. Attention! Only after the cement consolidates, nut of concrete bolts can be fastened After the adjustment, all the nuts on the adjustable mounts must be fastened. In order to prevent any damage due to the groundwork, it is recommended to check the plane situation after 4 weeks of operation. 1.5 Cooling Water Supply System The cooling water system pressure is 0.2~0.6 Mpa 1.5.1 Cooling water system layout There are three water circuits in cooling system: 1) Hydraulic cooling circuit 2) Screw and barrel cooling circuit. 3) Mould cooling circuit. The system supplies water to heater exchanger and cooling water manifold. Mould, screw and barrel cooling water have be given by the distributaries of water manifold, and thus to make efficient temperature control. Illustration OUT IN ee | .s, IN Motd/injection__OUT. —~base — Ww SP TO Other Cooling Systems Our Cooling Water Supply Flow Meter — (Can be supplied on demand) ouT co IN (| | Oil Cooler ) L— | 1.6.2 Discharge of Cooling Water ‘Stop supplying the cooling water and discharge the cooling water through the oll 1-10cooler after finished injection In winters, specially based on the weather conditions, the cooling water should kept its circling under comparative low pressure during machine's shut-down. (At night, in case that cooling water might be frozen, cooling water in the oil cooler should be discharged. The remaining water should be dried up by using compressed air in order to prevent damages of oil cooler and other equipment.) Note: TT = it is very important that all water to cool machine must be cleaned. If the cooling water is underground water or pond water unfiltered, the impurities might cause to block the filtering parts and pipe in the machine and affect the cooling efficiency of coolers. In that case we strongly recommend filter the cooling water before their use. Attention! An If the cooling water is taken from drinking water system, operators should ensure that no cooling water will be returned into the drinking water system. 1.5.3 Flow Rate of Cooling Water Changing the flow rate of cooling water according to many factors such as the injection conditions, water temperature, air temperature, the fact whether impurities is causing the oil cooler’s efficiency and etc. The flow rates in the following chart can be only used as reference not as requirement. Most appropriate flow rates are decided through actual plastic injection molding experiences. The Flow Rate of Cooling Water in Cooler Pump Driving Flow Rate Pump Driving Flow Rate motor Power motor Power 7BKW 43 Umin B5KW [94.5L/min | KW. 19 Umin 75KW 129 L/min KW. [26 Limin ‘S0KW 155 L/min 18. 5KW. 32 Umin T10KW, 180 Limin 22KW [38 Umin 135KW 234 Limin [30KW. 7 51.5 Umin 155KW. 269 L/min Is7KW (63.5 Uimin 220KW, [383 L/min 4a5KW 77.5 Limin 330KW. [576 Limin (CS Note: The temperature of hydraulic oil must not exceed 55°C when putting into use. The Cooling Water Flow Rate in mouldiwater manifold (based on molding conditions) | Heater Power [Cooling Water Flow) HeaterPower [Cooling Water Flow] | Rate Rate QQ QO wecenranmare 11TIANJIAN PLASTICS MACHINERY Chapter1 Installation and Alignment 10.5UMormore [40KW__+| 69.0 or more 12.0L/M or more 45KW___|__77.5L/M or more 13.5L/M or more BOKW | __86.0L/Mormore | 15.5L/M or more 55KW. 94.5L/M or more _| 17.5L/M or more 60KW 7103.0L/M or more 26.0L/Mormore | __S0KW 155LIM or more 34.5UMormore | 110KW (| _—_‘190L/M or more 43.0L/Mormore | __170KW ‘290L/M or more 51.5L/M or more 270KW, ‘460L/M or more 60.0L/M or more Attention! Inpouring of cooling water provides cooling function. Design of cooling equipment and pipe are based on that cooling water reaches 50°C. If you need to undertake heating operations to insulation soft pipe and molds, please contact our sales department. 1.6 Filling with Hydraulic Oil Through filling intake, pour in clean hydraulic oil until it reaches the up limit in the hydraulic meter (please refer to the Lubricant Chart Chapter 4.2 for the hydraulic oil type) After the completion of wiring, start the machine and check the oil position in the oil tank. If the oil reading is lower than the medium marking in the level indicator, add some hydraulic oil until the oil is higher than the medium marking .in general, it need to reaches 3/4 -4/Scapacity of oil tank. Please refer to Parameter sheet in Chapter 5 about oil tank volume for hydraulic oil supply amount. The real supply amount can larger than listed Attention! A Different brands or types of hydraulic oil must not be mixed. Within 3 hours after adding hydraulic oil, the oil pump cannot be started, which is to facilitate exhausting air inside the oil. 1.7 Power Supply Electrical equipment on the machine is designed in accordance with customer's requirements and in line with regulations laid down in the relevant countries. Electrical wiring can be done by consulting local electrical engineering company. In case of using 3-phase A/C power supply, a fuse with appropriate rating is needed. On the input connection panel connecting the electrical cable and electrical parts, the power supply is in 3-phase and 4-line. The voltage is 380V and frequency is 50Hz (except special condition). Please refer to the Parameter Chart in Chapter 5 for total power of machine. Other special voltage requests should inform the manufacturer in the order. JQ QQ QD wecwerenaee, 412Chapte 4 Installation and Alignment AN Attention Connection of power supply should only undertake by an experienced electrician > (CS Note! Please pay special attention to the fuse’s amperes and correct phase sequence. If the rotating direction of driving motor is reversed, it can be reversed back just by changing two-phase live wires on the input connection panel. Power supply voltage must be measured. Input power supply voltage should be in the range of + 10% of the rating voltage. Its frequency should be the rating frequency (with 1Hz deviation). If voltage deviation exceeds the above mentioned range, please contact the related power supply company. In order to avoid accidents caused by electricity leakage, a wire (its section area is listed the following chart) must be connected to the ground pole of machine on one end, On the other end, it must be connected to grounding pole or welded onto a copper plate then bury the grounding pole or copper plate inside the earth that is not easy to be dry. Motor Power | Conductor Size (Section Area) <15KW [ 14 mm? 15-37KW. 22 mm? >37KW. 38mm? 1.7.1 Check Rotating Direction of Pump Motor . a) Of pum motor sh When the power supply is connected, we must check the rotating direction of oil pump motor. Attention! JN Hydraulic oil must be filled to full! Before starting the oil pump, we must ensure that oil in the tank is full. > Turn on the power switch. > Tur on the oil pump motor switch briefly on the operation panel to run the oil pump motor then turn off immediately. > Check whether the rotating direction is same to the direction indicated by outside cover on the motor. O wecneaavesne, 113TIANJIAN PLASTICS MACHINERY Chapter Installation and Alignment In case that the direction is not correct, turn off the machine power supply switch and turn off the power supply switch on the power supply cable. Change the location of power input line L1 and L2 (see chapter8 main circuit) Attention! If the rotating direction of oil pump motor is not correct, it will damage the hydraulic oil pump. Note: (C$? Turn off the oil pump motor through oil pump motor switch on the operation panel. 1.8 Adjustable mounts Distance 16mm Adjustment (For large or middle-type machine) HT series of plastic injection molding machines can be fixed on the adjustable mounts and its anti-vibration function will make the machine operate quieter. After installing adjustable mounts, small machines do not need to be fixed on the ground by concrete bolts. Middle and big machines might be moved by the vibrations during the operation and must be fixed by concrete bolts. o 2 QQ Q wemnssene@: TIANJIAN PLASTICS MACHINER’ Chapter‘ Installation and Alignment Attention! All the supply lines, for exampie cooling water supply lines, must be flexible. Adjusting Adjustable mounts (mini-type machine) > Unfasten the nut (2) > Screw the bolt (1), until the mounts’ height reaches its minimal » Adjust machine by adjusting bolt (1) on all mounts. Please refer to chaptert.4 for operation in details > After the adjustment, fasten the nut (2) Adjusting adjustable mounts (large or middle machine) > Release adjusting bolt in anti clockwise direction » Adjusting all bolts to align the machine (see chapter 4 in detail) AN Attention Adjusting distance should not exceed 15mm; otherwise it will damage the adjustable mounts. 2 © wecewestmaee 1-16= TIANJIAN PLASTICS MACHINERY - -_ __Chapter2 Safety Chapter 2 Safety 2.1 General safety regulations Service, maintenance & repair work should only be carried out by personnel sufficiently qualified in their particular field and who have specific knowledge of injection moulding machinery. They should be versed in the maintenance of industrial health and safety standards and they should be familiar with the construction and functioning of the necessary safety equipment on the machine. If necessary, enlist the help of our service department. Attention! The safety equipment fitted on the machine is there for you safety A and that of the production of goods. The machine should only be operated when all ‘safety equipment is in working order. To remove, by-pass, or render safety equipment inoperative is therefore not permitted. The safety equipment also includes the safety program contained in the software. Don't carry out any changes to this program. If the safety equipment malfunctions or a fault occurs on it, the machine must be immediately shut down: » Actuate emergency stop button; > Main switch-off » Close down the cooling water supply after about 20 min The person in charge must be informed at once. Before putting the machine back into operation, the causes of the fault must be eliminated. 2.1.1 Machine main safety scutcheon | ] Scutcheon Sample Installation position | ° if | WARNING 2-45 SERIOUS INJURY CAN OCCUR IN i | CLAMP MOULD AREA WHEN THE OPERATOR GATE (S) |S OPEN WHILE CORE AND EJECTOR MOTION IS ON MOTION \| | RSA, SMBS RHA, | WRF GHW, UREA. Midland of moving platen in front side 21G TIANJIAN Chapter2 Safety Scutcheon Sample DURING NORMAL OPERATION, ae | OPEN THE ELECTRIC CABINET DOOR BEFORE OPEN THE ELECTRIC CABINET DOOR, PLEASE TURN THE POWER SUPPLY TO "OFF" POSITION. PRESLEN, MHTAR SEN. FAR BAIN, IRA ARE ON Orr” ei. (So CAUTION 3= 5% Handle dirty oilin time: Oil tap is used to drain out dirty oil, and tur it off in time when finished. RNA BUR E ARBOR ANS, HE RELA LTM CAUTION 3 Safely guard of nozzle must be closed before charging and injection. TEA. BN, De LOR. Installation position | - | Controller electric cabinet door Near the oil outlet Nozzle guarding cover Js B00 0 OO nierrmnne 23TIANJIAN PLASTICS MACHINERY Chapter2 Safety | Scutcheon Sample Installation position WARNING 265 | WHEN WORKING ON THIS MACHINE FOR PURPOSES OTHER THAN MOTOR (S) AND TURN POWER DISCONNECTS TO “OFF” POSITION LOCKS HOLD TO BE USED TO INSURE DICONNECT SECURITY. DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS THROUGHLY INSTRUCTED L ON OPERATING PROCEDURES. AEL(ERt, WHOS ARE) “OFF” ANE. ERSTEIIA, IRENE. Air switch in cabinet WARNING Fumes or vapors from some plastic raw materials used in this machine may be hazardous to your health. Before operating this machine, please obtain information from your materials supplier about the potential hazards of the raw materials you are using Follow all ventilation requirements and other recommendations of the materials suppliers. ERB RNARRUTVERAA, TRA RE RUS. AMA OR Mt T ARORA BR. | | (Qe | a SS Fa Barrel guarding cover 2200 29 OO ninmsnunne 2-5TIANJIAN PLASTICS MACHINERY Scutcheon Sample Chapter2 Safety Installation position oO 10 || | CAUTION 3 3 Please note the cleanliness of the oil in case of oiling. After some time of operation, clean the filter inside the tank. Tae, VRER MAE, (A ||| RATES, SoavtH Aaa. °° — oO Above oil intake and near the lubricating oll tank—each one (6 CAUTION 3 Please clean dust on the fan filter. TEAR LAKE. OV Above the filter SS . o oO CAUTION 32% While in running condition, please let the maintenance to do the troubleshooting if any alarm was given. METH, GRRE, ER BY AME HE A ADEE Below the alarm 24TIANJIAN PLASTICS MACHINERY Chapter2 Safety Scutcheon Sample Installation position Please read the USER'S MANUAL before operation, Do not operate this machine without operator gate(s) and/or guard(s) in position. At the start of each shift and after each mold change, check the operation of the front gate limit switch, hydraulic interlock valve, platen stop bar | and stop plate, rear guard and rear fixed guard, front fixed guard. Do not operate this machine unless all interlocks andior devices funotion are right. PANBTAAAERARES. FESAPIRACS AGN, AHERN. Be BNRALE, PAAMGPITRAR. MESS, BRE. ABP. ERAS. Operating panel box DANGER fi DO NOT OPERATE THIS MACHINE WITH REAR GUARD OPEN OR REMOVED. THIS GUARD IS NOT TO BE USED AS AN OPERATING GATE, MECHANICAL STOP NOT PROVIDED. MOTOR MUST STOP WHEN GUARD IS OPEN OR REMOVED. PSTN, TERR BN. BP RATE, BRAUER. TTAB r SABA. }02H 00.000 Rear safety guard 26TIANJIAN PLASTICS MACHINERY Chapter2 Safety Scutcheon Sample ] Installation position DANGER Je ke DO NOT OPERATE MACHINE WITH a | | Hopper HOPPER REMOVED OR WHILE |_|) CLEARING OBSTRUCTIONS. FERS REDO SLR, EERIE | Electric cabinet cover or | barrel cover which voltage above 36V. | ° ) | eS 27@ TIANIIAN Chapter2 Safety Installation position Hopper cover Automatic safety door = | 22H 00 2 OD wecrannnaee 28& TIANIAN Chapter2 Safety | Scutcheon Sample Installation position tance mechine novia guerd_| Front and rear side—each one 2.1.2 Maintenance & repair work Attention! rN All repair and maintenance work should only be undertaken when the main switch on the injection moulding machine is switched to" 0" if necessary, is locked by padlock. It is the employer's duty to instruct the machine operator on the construction operation and function of the safety equipment as well as on the correct altitude to health and safety at work. Attention! ‘Any process which impairs safety on the machine should be stopped. The employer must ensure that no unauthorized personnel work on the machine, No safety equipment whatever should be taken off the machine or put out of action. If it is essential to remove safety equipment in order to carry out repair work, then it should ensure safety. As soon as the repair work is completed, the safety equipment must be refitted and its effectiveness checked 2000 OOO nicssininnn 29TIAN, PLASTICS MACHINERY 7.4.2 Injection Valve Manifold (JLY-585029A) Designed/Date: Qiu Yajie 2010-03. /Date: Mei Quanlon: a LPVPOLLLLYO merrsomee 7-6TIANJIAN PLASTICS MACHINERY Chapter2 Safety Note: We strongly stress that it must retract the nozzle to leave the mold, stop pump motor and open the guard before you enter the clamping space to clean or repair. 2.2 Safety equipment 2.2.1 General equipment The safety equipment consists of guarding and locking mechanisms. > The guard panels prevent access to the danger areas and protect personnel from plasticising melt spurting out > When a particular guard panel is opened, locking mechanisms interrupted any dangerous machine movement. The measurements for the moveable guarding in the mould area and for the __ component ejection opening are designed in such a way that there is sufficient safety margin, for the larger moulds are concerned, the measurements of the guarding panels are required to be added relatively. 2.2.2 Safety equipment (illustration only for reference, actual machine may be differ with it) “e/a Position Description Movable guarding in the mould area—operator side/non operator side [ Nozzle guarding Fixed guarding on the injection unit—operator side Fixed guarding on the clamping unit—operator side/non operator side Fixed quarding on the clamping unit-side. Hydraulic safety valve Z Mechanical safety unit Electrical safety unit Barrel heating guarding Fixed guarding -front B]o\e|~1)oo}or]a]eo|r9] 2.2.3 Moveable guarding in the mould area Member afhten | 2 DEVO O20 OO wrewersnminTIANJIAN PLASTICS MACHINERY 7.3 Hydraulic Components List No] Symbol | Code_| Name Moder Description Remark ot fh JortR —_fooosao FEC Iszevz001-6. 18.5KW,380vi60HZ|Drive pump 2 |p 190001 _|Vane Pump |35v30A-18-22-R System drive source |VICKERS Hi Is |r fraat00 YSU Niran44-700.040 Drive charge Motor IHydraul le m2 |113008 finer |uA-t60. 013-0014 [Drive mold adjustment |eaTON o_ FA 130000 _|Filter WU-160X100-J Filter oil ls _|r2 132001 [Oil_tevel__|yw2-127 Oil level & temperature| 7 les 131000 [Suction |FsB.25.6M Filter air Heat le ra 139021 |echanger_[St-41SU1FT Lower oil temp. o_|v7 125003 _|Valve JEFBG-03-125-C-15 |System press. & flow Ho [ve 122193 [Valve JAWEHIBEA7X/6SG24N9ETK4 [Control charge motion [REXROTH (Adjust charge and M1 |V10 1254009 |Valve EBG-03-A-45-R lback pressure 2 [vit [122168 [Valve JAWEHIGEATX/6SG24NSETK4 __|Injection & suck back _|REXROTH 3 |vi2___ [122125 [Valve |AWESEGX/SG24NSKA INozzie move IREXROTH 14 [vis {124010 |Valve MC-02P-05-20 Nozzle adv and Fold 15 [V16 122125 _|Valve |J4WEBEGX/SG24NSK4 Core Bin & out OPTIONAL. 16 _|v20 122125 _|Valve JAWESEGXISG24NOKS [Core Ain & out IREXROTH 17 |v22 122215 _|Valve |SWH-G03-C22-02420-Mis Ejector move 18 |v25.1__ [848943 [Valve \T-09-181-00. Hydraulic safety [Controt_moid clamp] 9 \v26 122137 |Valve |4WEH16Y317X/6SG24N9K4 land differential REXROTH bo vor Iraotaa \Vvane fWEnreerwascoenseKarerorg IMold open & close Rexko= j21_|v28 122125 _|Valve AWESE6X/SG24N9K4 Mold adjustment motor|REXROTH | I [Control mold open and| j22 |v2a | 122121 Valve lawescexisc24noKa back pres. IREXROTH leaaies |, Mold open & close| Ps ¥30__lecasor_\VeNe LOP1G-D-TAMXA land back pressure iRiessure System —__pressure| lea fer 195018 |aauge 1453/0-25MPa, panel latptey [TEcsis Pressure Charge and back| los |e2 135017 Gouge 1453/0-16MPa, panel preseare ITEcsis Note: We have the rights of changing hydraulic components model in case of special requests or further technical development. Model in detail should be found on the machine you order. Designed/Date: jiu Yajie 2010-03-06 LPLOWVLLD D wenn Checked/Date: Mei Quanlong 2010. 7-4TIANJIAN PLASTICS MACHINERY : Chapter? Safety Attention! I If changes for a new mould in A type mode, the rod positions alter together with adjustable bolts, so as to ensure a proper space for safely clamping mold. That is to say, when the guarding door is opened and the mold opening reaches to the limitation, the drop bar must be dropped. If changes for a new mould in B type mode, the rod positions don’t alter together with adjustable bolts. The above relevant parts of the mechanical safety unit must be checked regularly. Once there is something broken, it must be repaired or changed immediately. Hydraulic protection safety valve is functioned directly by means of blocking clamping oil circuit, to stop mold clamping movements. The electrical protection is realized by safety stroke switch; thus all possible clamping instructions are stopped in the electrical system. Error message: If the machine is started up and the guard door is left open, an error message will appear on the display screen of the operating panel: “Guard door is not closed!” Error message elimination: Close guard door: Keep checking stroke switch or adjust as well as repair stroke switch until the error message is canceled; Error message can automatic canceled after all error messages are disposed. 2.2.4 Nozzle guarding To prevent the scorching plastic liquid gushing out to scald machine operators, metallic nozzle ‘cover is installed on the nozzle working position. On the top of the nozzle cover, there is a moveable canopy with a viewing window, upon which a safety stroke switch has been installed When opening the nozzle guard cover, " Injection carriage forward ", " injection ", "Charge" are completely stopped (A certain series of machines may have some little differences with the aforementioned due to configurations), and automatic and semi-automatic operations are cancelled. 3098005000... 2-12-14TIANJIAN PLASTICS MACHINERY Chapter2 Safety The hydraulic safety equipment consists of pressure relief valves, which the manufacturer has set to the maximum permissible value and then sealed. The valves are actuated when the pressure exceeds that which has been set in accordance with the specified value Pressure relief valve limits hydraulic system pressure and this protects the operator and the hose and pipe connections from excessive pressure. This prevents damage as damage as a result of faults in the hydraulic system. Pressure relief valve protects the variable pumps in the hydraulic drive from overloading Attention! Under no circumstances must pressure relief valves be adjusted. 2.4 Electrical safety equipment The electrical safety equipment consists basically of the ground connections and the emergency stop button. Earth wire connections on all electrical equipment on the machine particularly electrical heating equipment, heater bands must be checked periodically. The emergency stop button is located on operating plate and non-operating fixed mould guarding plate. If pressure the button, various machine movements are immediately brought to a halt, Both the pump motor and any handling equipment fitted via the standard interface will also switched off. For safety reasons, once the emergency-stop button has been actuated, the machine will remain in the stop position. The error message "emergency-stop actuated" appears on the operating plate screen The button is released by turning the knob a quarter turn The cycle can then be restarted and the error message disappears Breaker has under-voltage protection. 2.5 Checking the safety equipment JN Attention! When a customer accepts a machine, the responsibility for servicing and testing the safety equipment passes to him. If the fault is discovered on the safety equipment, the machine must be taken out of service immediately. The causes of the faults must be eliminated before the machine goes back into operation. We recommend the following checks be made on the safety equipment F222 DQ OQ wenmernmone cena ee D 214TIANJIAN PLASTICS MACHINERY 7.1 Hydraulic Circuit DesignediD: 6 __Checked/Date: Mei Quanlong 201 AMemberof ata » QLD QLQD D> D ween 5 7-2TIANJIAN PLASTICS MACHI Chapter3 Putting Into Operation Chapter3 Putting into operation 3.1.Preparatory work c+ Note: Before operating the machine, please read Chapter9 carefully to get familiar with the way of operation to the controlling system. Only after that may come to the following debugging and adjustment. 3.1.1. Correct clothing cr > ——+—__ safety heimet u 27 — PPE gloves a: ( 63 Work ciothes or overall (Be ———--—___sure to fasten the buttons) | Safety boots or shoes Li} Gan MED 3.1.2. Necessary jobs before testing the new machine > Check and ensure that the machine has been well installed, including correct leveling, correct connection of the parts, electrical cables and oil pipes removed during transportation, removal of the additional parts added for transportation and lifting >» Check the power supply and earth lines have been properly connected, cooling water properly connected and opened for use. > Check the hydraulic oil has reached above the middle line of the cil level meter and maintained for more than 3 hours. > Check the surfaces of all the motional parts have been cleaned and lubricated 3.2. Testing and adjusting the new machine 3.2.1 Power on ‘After whether voltage and frequency complying with the request of main motor is checked. Connect the power supply line, set the power switch on the machine upward to Position ON to power the machine. There are some protective switches in the electric cabinet. Open the door of the cabinet, put all the mini circuit breaker (see chapter8 component layout) upwards in the cabinet to connect all circuit. If LCD screen displays menu means the controller is 3-4TIANJIAN PLASTICS MACHINERY 6.12 Nozzle 942 SR10 oS : . A « | 2 A 5 iN 918 935 M39X2 Designed/Date: Zhang Yu 2009-3-9 __Checked/Date: Mei Quanlong 2009-3-9 BP OLLLLLO means 6.24TIANJIAN PLASTICS MACHINERY Chapter3 Putting Into Operation semi-automatic mode. At the End of one circulation, if no abnormality occurs, re-switch on/off for another time to enter another round of circulation. ‘After 3-5 circulation of normal work in the semi-automatic mode, at the end of the mould closure, push the time automation key to give the fully automatic work mode to the machine and observe if the machine works normally. Normal results of all the a/m tests indicate the completion of tests and possibility to conduct the plastic injection and molding If your injection molding machine be installed with SIEMENS controller, after manual mode in good condition, debugging semi-automatic and full automatic as follows: Semi-autonmatic (for SIEMENS) > Press functioning key of every motion > Let the motive unit or part to its original position of setting > Confirmed by screen indication, press semi-automatic functioning key, then press semi-automatic start key. machine work in semi-automatic mode. Testing whether semi-automatic mode is in good condition. If these are no faults, stop the semi-automatic circulation after repeating 3-5 circulations. > Full-automatic (for SIEMENS) > Ensure the motive unit or part is in there original position. If not, resetting it > Press full-automatic functioning key, then press full-automatic start key. > Debugging and adjusting the full automatic function until it's in good condition. Normal results of all the a/m tests indicate the completion of tests and possibility to conduct the plastic injection and molding 3.3.Procedure of the mould installation 3.3.1.Preparation Measure the length, width and height of the mould. Compare the measured data with those in the parameters sheet(see chapter5) and determine if the mould can be set on the machine. Measure the diameter of the mould locating ring to make sure it can fit the installation holes in the fixed platen. Measure the flow gate dimensions and distance between flow gate and installation plane of fixed platen. Check whether it can match to nozzle of machine Measure mould ejection platen; check it can match to relative parameters (see chapter) on the machine in manual thick adjusting mode, adjusting the mould height available according to mould’s actual height. Setting opening stroke according to the space distance which products can drop freely. Setting ejector stroke to ensure the mould would not be a) 2 rene tanrar, 33TIANJ IAN PLASTICS AGHENERY 6.11 Screw ant Barrel igned/Dat 3-9 __Checked/Date: Mei Quani ‘Atmember of sian trea LLOLLQYYQ@ Q wewmsenaay.Gy TIANJIAN PLASTICS MACHINERY Chapter3 Putting Into Operation Attention! (> forthe size of the bolt see the mechanical drawing in Chapter5 .Depth H of the bolt shall be 1.5~1.8 folds as large as its diameter 2. Step 8: Start running the oil pump motor. Fastening bot Step 9: Close the mould in way of step move to let the mobile part of the mould approach the fixed part until a tight fitting is achieved. cuice orate Step 10:After full closure of the mould, aligning — nozzle center to ensure nozzle center aim at mould flow gate center. Aligning procedure as follows:(see Fig1,2) > Unscrew the fastening bolt (Fig1) and locking nut (Fig2) > Adjusting nozzle height by nozzle adjusting bolt. > Adjusting nozzle right or left direction by right or left adjusting bolt > Tighten fastening bolt and locking nut after end of alignment. Locking put Serew are base voz asusing ot] Botadjusing_nozze\ ‘ight orl Fig2 material let to ascertain if there is any conflict which may lead to a Attention! Jv Before moving the nozzle observe its length and the depth of the damage of the nozzle or the heating coil. Step 11: Tur off the oil pump motor, Step 12: Tighten up the clamping bolt fo mounting fixed parts of mould to fixed platen firmly, Step 13: Tighten up the clamping bolt to mounting movable parts of mould to moving platen firmly as the same way. 3-5TIANJIAN PLASTICS MACHINERY 6.10 Screw Drive Assembly 2 f N SS Shy \ \ \ \ \ |. \ LN Se \ SN SLs | | de shes ned/Date: Zhai 2009-3-9 __ Checked/Date: Mg! Quaniong 2009-3-9 tan re BLO LLLLQ MQ memset, 6-20TIANJIAN PLASTICS MACHINERY Chapter3 Putting Into Operation no load, for the heating. May also exercise some motion, for example, to drive the rotation onwards and backwards. Set a certain pressure and flow this will result in a quicker rise of the oil temperature. 3.4.3.Procedure of the plastic injection Step 1: Set the heating temperature of the material barrel to a point suitable for the material to be used. And start next step only after 15 minutes from the moment when the temperature of the material reaches the set point Step 2: Open the cover of the material hopper, pour the plastic material into the latter, Replace the cover back (follow the operation instruction if there is an automatic material loading device) Step 3: Roughly set up the position of the end ,pressure and speed of the material storage according to the weight of the product and the specific weight of the material. Adjustment of charging back pressure have two different methods according to machines type. > For machine which clamping force above 800 Ton, back pressure can be adjusted by setting corresponding valve in operating panel > Mini type machine can only be adjusted by means of manual adjusting back pressure valve which installed on the injection oil circuit. Valve can be read by back pressure gauge installed near the back pressure valve or injection guard. There are obviously mark near the gauge. Note: (= Too big back pressure may increase the energy consumption during the charging process. Step 4: Press the start key of the motor to start running the motor; Step 5: Press the mould-closing key to do the mould-closing motion until the end of mould closure. Step 6; Hold the advancing key of the injection base to advance the injection base until the nozzle is in contact with the injection orifice of the mould Attention: CS For different plastic materials and moulds, The order of Step 5 and Step 6 can be inverted. Step 7: Press the charge key, at which the screw rotates and gradually moves back to the set position. After that charge stops automatically. May also press charge key again to stop charge. ‘Step 8: Press the injection key to start injection action and pressure-keeping ¢3 © snecone sear. az