ENGEL | care

Maintenance Protocol

complete
Safety-check / Inspection 
Fluid Service 
Testing & Measurements 
Calibration 

Additional service
Oil sample 
Temperature measurement 0
Tie bar extension 0
Mold change unit (famox) 0
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

1. Data General

Customer Global percision

Date of Maintenance 30/06/2021

Technician D. Hope

CS-order

2. Data Machine

Machine group VC 650/150 TECH

Serial number 44799

Customer machine identification n/a

Operating hours 1002069

Manufacture date 2001

Control system CC100/EC100

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Management Summary
Customer contact person: Nigel

Touchscreen or LCD

LCD screen has lost pixels across screen.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Alarm lamp

Not working.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Stroke transducer: closing unit

Reader face has come away from transducer - replacement required.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Leakage: Injection cylinder(s)

Injection cylinders leaking from front seals - both sides.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Leakage: Carriage cylinder(s)

Both sides leaking from endcap seals.

Replacement Parts
 Service Quotation  Picture Number
Quotation

3/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Management Summary

Leakage: Hoses

All over due changing.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Replace hoses every 6 years.

All over due changing.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Check condition of hydraulic hoses

All over due changing.

Replacement Parts
 Service Quotation  Picture Number
Quotation

Plate parallelism

Tool in press

Replacement Parts
 Service Quotation  Picture Number
Quotation

Nozzle alignment

Tool in press

Replacement Parts
 Service Quotation  Picture Number
Quotation

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Management Summary

Leveling

Out of tolerance - relevelling required

Replacement Parts
 Service Quotation  Picture Number
Quotation

Technician Comment

Injection cylidners both sides - leaking from from seals. Carriage cylinders both
sides - leaking from endcap seals. Closing transducer is damaged - replacement
required.

5/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Controls Checked Result

Touchscreen or LCD  
Soft-keys  
Buttons for machine movement  
Alarm lamp  
Key switches  
USB- / Floppy- or cassette mechanism  

Machine control Checked Result

Voltage back-up battery  
Wiring  
Ground connection  
Connectors and plugs secured  
Conduit to HMI  
Cooling fans  
Machine floppy or -cassette back up  
Drive controller  

Control cabinet Checked Result

Fuse  
Relays  
Din rails  
Wiring  
Main current  
Power socket  
Cooling fans  
Designation of components  

6/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Control cabinet Checked Result

Necessary shielding high voltage current  

Barrel heating fuses Checked Result

Wiring of the heat bands  
Thermocouple  
Labeling of heating zones  
Temperature fluctuations  

Cooling system Checked Result

Temperature oil cooling in manual mode  
Hose/piping oil cooling system  
Temperature travers cooling in manual mode  
Hose/piping travers cooling system  
Flomo or water distributer  
Motor cooling  
Hose/piping motor cooling system  

Drives Checked Result

Variable displacement pump(s)  
Coupling between motor and pump (Rotex)  
Motor (sound, bearing)  

Injection unit Checked Result

Pressure drop: contact force  
Contact force tie rod couplings  
Carriage stroke transducer  
Guide rail system  
Valve block: injection unit  
Barrel securing system (quick change system)  
Nozzle safety gate protection mechanics  

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Injection unit Checked Result

Ball screw injection unit  

Injection / Plasticizing Checked Result

Screw Coupling  
Injection stroke transducer  
Material cushion constant  
Valve block: Injection / Plasticizing  
Hydraulic motor / Plasticizing Transmission  
Screw rotation speed inductive sensor (impulse transducer)  
Screw drive-shaft bearing  
Barrel support  

Closing unit Checked Result

Guide rail system  
Central lubrication moving platen  
Stroke transducer: closing unit  

Open / close form Checked Result

Mold protection  
Clamping force: Build up and reduction  
Valves block: Closing unit  
Speeds: Opening / Closing  
Pressure transducer: Clamping force  

Ejector / Core pull Checked Result

Ejector coupling  
Valve block: Ejector  
Stroke transducer: Ejector  
Speeds: Ejector / Core  

8/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Ejector / Core pull Checked Result

Pressure / Force: Ejector / Core  

Filter / Contamination Checked Result

High - or low-pressure filter  
Cleanliness/Condition: overall state of machine  
Cleanliness/Condition: motor cooling  
Cleanliness/Condition: card rack  
Cleanliness/Condition: control cabinet  
Dust filter  
Air filter main tank  
Condition: Oil  

Sealing of the Hydraulic system Checked Result

Leakage: Pump block(s)  
Leakage: P-Q block  
Leakage: Closing block  
Leakage: Various blocks  
Leakage: Closing cylinder  
Leakage: Injection cylinder(s)  
Leakage: Carriage cylinder(s)  
Leakage: Ejector cylinder  
Leakage: Hoses  
Leakage: Pumps  
Leakage: Hydraulic motor / Plasticizing Transmission  
Leakage: Couplings / Fittings  
Leakage: Closing bearing housing  
Leakage: Injection bearing housing  

9/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Sealing of the Hydraulic system Checked Result

Leakage: Contact force bearing housing  
Leakage: Cooling system  

Note for preventive exchange Checked Result

Replace hoses every 6 years.  
Replace filter every year.  

Safety devices Checked Result

Hydraulic (electric) closing protection  
Mechanical closing safety  
Safety gate operator side  
Safety gate non operator side  
Nozzle safety gate and safety guarding  
Emergency stop functional  
Electrical safety: Mold closing  
Plexiglass damaged  
Safety guarding / Protective covers  
Motor stop (DC link relief) (check discharge)  
All required ground wires secured (correctly)  
Emergency stop: Check voltage shutdown  
Check condition of hydraulic hoses  
Check warning labels  

10/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Summary

Testing & Measurements

Supply voltage Display set value 

Plate parallelism Difference 
Nozzle alignment Difference 
Leveling Difference 
Heating Power 
Stroke measurement Display set value 
Pressure measurement Actual value / Linearity 
Injection pressure Linearity 
Injection speed Linearity 
Screw rotation speed Linearity 
Non return valve Sealing 

Calibration

Stroke measurement Calibrated without adjustment

Pressure measurement Calibrated without adjustment
Injection pressure Calibrated without adjustment
Injection speed Calibrated without adjustment
Screw rotation speed Calibrated without adjustment

The listed points shown above were calibrated by the ENGEL technician.
It’s possible that a readjustment was necessary, and the process data settings
must be aligned.

11/19
VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Supply voltage

Main connection Supply voltage AC

Actual value (Lx to
Name (LX4) Actual value
PE

L1 239.4V LA1 0.0V

L2 241.8V LA2 252.3V
L3 241.8V LA3 0.0V
LA4 26.2V
LA5 26.2V
Supply voltage DC
Set value (E-
Name (LX4) DC AC rate
Diagram)

LD1 / PE 0.0V 0.0V 0.0V

LD3 / 24VC 24.0V 28.9V 0.0V
LD4 / 24VE 24.0V 28.6V 0.3V
LD5 / 24VK 24.0V 28.6V 0.3V
LD6 / 24VKN 24.0V 28.7V 0.3V
LD7 / 24VK1 24.0V 28.7V 0.3V
D15 / 24VKS 24.0V 28.2V 0.3V
D16 / 24VK1S 24.0V 28.8V 0.3V
VR1 n/a n/a n/a
VRS2 n/a n/a n/a
n/a n/a n/a
Transformer
Motors running DC AC rate

LD1 / 24VH 0.0V 0.0V

LD4/5/6/7(D15/D16) / 24VK 28.6V 0.3V
LD3 / 24VL 28.6V 0.3V

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Plate parallelism

Maximum difference 0.00 mm

Tolerance 0.00 mm

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Nozzle alignment

Measured values

M1
M2
M3
M4

Deviation vertical

Deviation horizontal

Centering tolerance 0.20 mm

Deviation 0.00 mm

M3 M4

M2

M1

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Leveling

2 4
3
1

Measuring direction

Longitudinal measurement closing unit [ 1 ]

Operator side
 0.4 mm/m   x 
Non operator side
 0.4 mm/m   x 

Cross measurement closing unit [ 2 ]

<- Operator side Non-operator side ->
 1.0 mm/m 

Longitudinal measurement injection unit [ 3 ]

Operator side
 0.5 mm/m   x 
Non operator side
 0.4 mm/m   x 

Cross measurement injection unit [ 4 ]

<- Operator side Non-operator side ->
 1.0 mm/m 

Vertical position (inclination)

Moving platen  x 
Fixed platen  x 

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Heating

Cylinder heating 1
Heating
Electric power Power consumption Result
zone

Zone1 294 W 1.22 A 

Zone2 2555 W 10.60 A 
Zone3 2964 W 12.30 A 
Zone4 3013 W 12.50 A 
Zone5 3543 W 14.70 A 
Zone6 - -
Zone7 - -
Zone8 - -
Zone9 - -
Zone10 - -
Zone11 - -
Zone12 - -
Zone13 - -
Zone14 - -
Zone15 - -

Cylinder heating 2
Heating
Electric power Power consumption Result
zone

Zone1 - -
Zone2 - -
Zone3 - -
Zone4 - -
Zone5 - -
Zone6 - -
Zone7 - -
Zone8 - -
Zone9 - -
Zone10 - -
Zone11 - -
Zone12 - -
Zone13 - -
Zone14 - -
Zone15 - -

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Pressure measurement

Pump pressures
Display Display Display Display
screen gauge screen gauge

Set value Pump: 1 Pump:

30.0 bar n/a n/a No function to set individual
80.0 bar n/a n/a pressures
max. n/a n/a n/a n/a

Clamping force & contact force

Set value Max. CF = 1500 kN Contact force unit 1
50% 105.0 bar 108.3 bar 85.0 bar
100% 212.3 bar 210.0 bar 160.0 bar

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Injection unit 1

Injection speed
max. Injection speed 84 mm/s
Set value - Speed Actual value - Speed
8 mm/s 8 mm/s
42 mm/s 42 mm/s
84 mm/s 84 mm/s

Injection pressure
Max. injection pressure 180.0 bar
Actual value injection pressure Set value injection pressure
18.0 bar 18.0 bar
90.0 bar 90.0 bar
180.0 bar 180.0 bar

Screw rotation speed

max. screw rotation speed 290 U/min
Set value screw rotation speed Actual screw rotation speed
29 U/min 29 U/min
145 U/min 146 U/min
290 U/min 293 U/min

Non return valve

Screwpostion at switch over (C3u) 8.00 mm
Screwpostion after holding pressure (CPx) 7.80 mm
Calculated screw speed 0.02 mm/s
Specified limiting values 0.10 mm/s

Material used during testing

HDPE

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VC 650/150 TECH Fabr.-Nr: 44799
30/06/2021

Testing & Measurements

Stroke measurement

min. max. offset max. Weg

Form 908 8536 981 606.0 mm

Auswerfer 241 5687 0 130.0 mm

Aggregat 1 105 9315 2558 350.0 mm

Schnecke 1 513 8932 0 200.0 mm

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