1.3.1 Mechanical Danger

1.3.2 High-pressure Leakage Danger

1.3.3 Burning Danger

1.3.4 Explosion Danger

1.3.5 Electrical Danger

The injection moulding machine operates with high voltage and large electrical currents. The power requirements are marked on the electric nameplate on the machine frame and in the electrical drawings. The equipment must be connected in accordance with the circuit shown and comply with all applicable provisions of your local regulations.

1.3.6 Noise

Under normal operating conditions, the injection moulding machine's noise emissions will not cause harm. However, long-term exposure to excessive noise may damage hearing. Ensure that noise levels are not higher than local laws permit. Wear hearing protection equipment during operation.

1.3.7 Gas, steam, and dust emission

Some materials will emit harmful gases, steam, or dust. Please install exhaust systems according to local regulations.

1.3.8 Slip, trip, or fall

It is prohibited to walk, stand, climb, or sit on the machine. Use a qualified platform or ladder to reach high places.

1.3.9 Hoisting

When hoisting the machine or machine parts, it is important to use appropriate lifting equipment, apply the right balancing techniques, and use designated lifting points. For handling and lifting descriptions, please refer to the installation details in this manual. Overloading the lifting capacity of the equipment is not allowed.

1.6.1 Safety Cover and Safety Door

1.6.2 Mechanical safety device

The mechanical safety device is important to protect the safety of the operator and mould. The principle is: When the safety door is opened, the shield falls to cover the hole, preventing the safety rod from closing, which stops mould closing. You must confirm the device works well and do not disassemble it. Notice: Check and adjust the device regularly to confirm that when the safety door is opened, the shield falls freely and covers the hole. You should test it multiple times after adjusting. When the safety door is closed, make sure a distance of 3~5mm exists between the bottom of the safety bar and the shield to avoid the line becoming tense.

1.6.3 Electric safety device

Electric safety devices include the air switch, breaker, earth line, emergency stop switch, and all limit switches of the safety doors. Machines have clear earth connection marks to remind users. The emergency stop button is set up at the operation panel and the protective board of the non-operating fixed platen separately. If you press this button, the machine will stop all actions immediately, including the pump motor (but still heating). All equipment connected with the standard interface will also be closed. At this time, the screen will display information regarding the "open manually stop button." If you want to restart the machine, please rotate the button clockwise. The front door has two limit switches, and the back door has one (or two) limit switches, chained up to the front and back doors respectively. When the security door is opened, the machine cannot be clamped. Check the front door limit switch: if the security door is opened by about 50mm, the machine will not be able to clamp. Check the back door limit switch: if opened more than 20mm, it should not clamp. (On some models, the pump motor will be cut off when the door is opened). Depending on the model, the security door limit switch may be mounted on the upper part of the operation box or another location. When the limit switch acts, "Injection", "Charge", and "Nozzle Move" will not be allowed. Semi-automatic and fully automatic states will break. Notice: Must check the reliability of all limit switches and the emergency stop switch every day. You must replace them immediately if you find any failure or damage.

1.6.4 Hydraulic Safety Device

Notice! Safety equipments listed above are optional devices; if you need them, you should indicate this before ordering. Notice! You cannot adjust or disassemble the system safety valve.

• A. Security door hydraulic protective valve (cam valve): when the front security door is opened, the clamping hydraulic circuit is cut off through the cam valve, making a stop mode.

• B. System safety valve: The manufacturer has set the maximum allowable value and sealed it, limiting the maximum system pressure. If the pressure exceeds the specified value, the system will open the safety valve. The safety valve limits the pressure of the hydraulic system and protects operators and hydraulic components, such as pumps and pipe fittings.

1.6.5 Feed platform

TEDERIC highly suggests users adopt an autoloader to feed the material into the hopper or hopper dryer. If the operator feeds manually, then the platform should be produced in accordance with the EN ISO 14122 standard. Tederic can also be requested to assist in designing or providing this feed platform. Notice: Even if there is a feed platform, the operator at the feed hopper must look out for personal injuries caused by slipping.

2.3.1 Request to quality of water

Cooling water must be clean. We suggest filtering equipment for the water supply system. Dirt produced by unclean or unfiltered cooling water will block the components and the pipelines, badly impacting the cooling effects, and leading to malfunction and damage to the machine.

2.3.2 Water pressure

3~6 bar. The water temperature should not be more than 20°C. For water-saving, we suggest the use of recycled water.

2.3.3 Cooling water flow

2.4.1 Brand

2.4.2 Request to quality

NAS1635 (American standard) Grade 7 to Grade 9. Notice: A. Strictly prohibit recycled oil; B. Cannot mix and use different brands or models of hydraulic oil; C. Cannot use hydraulic oil that has been kept for more than 2 years.

2.4.3 Oil tank capacity

Each machine requires hydraulic oil for the tank. For other machine models, you may consult the D series and prepare the liter request according to the clamping force.

2.4.4 Lubrication oil and grease

2.4.5 Request to lubrication oil quality and introduction

Instruction for use: recommend 00# lithium base grease. Check the oil relief ball valve regularly to prevent the lubricating oil from overflowing the waste oil plate. Notice: A. Strictly prohibit recycled oil; B. Cannot mix and use different brands or models of hydraulic oil.

3.1.1 Preparation

• A. Before lifting, make sure the moving platen is at the location of smallest mould thickness.

• B. Ensure you have a crane or other lifting equipment, hooks, tape or rope. For the weight of the machines, please see the technical parameters table.

• C. Have some blocks or useless cloth available.

• D. Ensure a good condition foundation, or a solid and smooth concrete ground.

3.1.2 Lifting notice

• A. The sling cannot be connected with the weaker bearing parts of the machine. It should be operated strictly according to the sketch map.

• B. Lifting and installation should be operated by skilled workers.

• C. The injection moulding machine may only be lifted and moved horizontally, using the provided lifting and transport elements. It is essential that the slings are prevented from slipping!

• D. No persons are to stand or linger under the suspended load.

3.1.3 Lifting sketch map for two-platen machine Separate frame

Check that the back part of the tie bar is tightened together with the frame by a solid wire before lifting, making sure the moulding platen and the frame will not separate when lifting. The clamping unit is indicated as shown above; use the template fixing bracket 900001.032 to connect the front and the moving template. When lifting the clamping unit, you must lift the front panel with the lifting rope and the lifting ring of the mould body tail, but do not allow lifting rods. When the machine is installed, remove the stencil holder. For the front template and the rod that is not divided, the lower rod goes through the support frame 900001.031201 and is fixed by the pressure plate 900001.0313, with a convenient rubber pad. Lifting rings can be lifted on the front panel. When the front template, moving template, and the machine are to lock the body, the slider is lifted with the lock body. The slippery foot is fixed to the lock body by means of a slide foot fixing plate 900001.0311. Notes: 1. DH480, DH550, DH680: the clamping unit is lifted together with the fuselage. 2. DH850, DH1400: the clamping unit and the fuselage are divided, but the front part of the clamping unit and the rod are not divided. 3. DH1700-DH7000: the clamping unit, clamping unit frame, and injection unit are separated for packing and shipping, so lifting is also separate. The safety doors and covers are also packed separately.

3.2.1 Connect the machine

The frame of a two-platen machine adopts a fission style. After lifting and placing the machine in position, please connect the injection unit and clamping unit, then you can make the further installation and adjustment. Steps for connecting the frame:

1. 1. According to the position shown in the groundsill drawing and machine shape drawing, please place the machine leveling pad or armor plate around the foot bolt on the regular groundsill. Please refer to the concerning part for specifications.

2. 2. As per the lifting drawing, lay the clamping unit on machine leveling pads or armor plates; then lift the injection unit to the relevant position, paying attention to the holes on the machine leveling pads which must be in contraposition to the machine frame, then you can pull the bolt into the frame. Fix the washer and nut, then screw them down.

3. 3. Through the initial leveling adjustment and aiming for correct nozzle alignment, tie the nut completely.

4. 4. Fit on all clapboards.

3.2.2 Machine cleanness

Through the shipment, lifting, and installment, the machine will become dirty. There are also some parts on the surface of the machine that were applied with antirust paint; you must clean it after placing the machine in position. Please note: 1. It is not allowed to use any chemical solvent to clean out the antirust and dust. 2. Pay special attention to cleaning the dunghill from the piston bar, guide bar, and tie bar to protect the oil sealing.

4.2.1 The adjustment of the leveling tolerance

In order to keep the machine running stably, this proceeding must be adjusted carefully and exactly.

4.2.1.1 Leveling tolerance adjustment for the medium size and big size machine (Two part frame)

Steps for adjusting:

1. 1. Please clean the foundation before installing the machine, place the leveling pads according to the dimensions showed in the foundation installment drawing enclosed in manual part two, lift the unit up stably until 500mm from the ground, point the foundation bolt upward to the frame hole, put on the flat washer, spring washer & nut to the bolt, turn the nut in and keep the bolt upper end out of the nut by 5~10mm.

2. 2. Put the machine under the leveling pads. Please see to it that the foundation bolt meets the foundation hole, then refer to section 3.3.1 to connect the injection unit and clamping unit substance.

3. 3. Make sure the machine is set to the minimum mould height.

4. 4. Place the Gradienter as shown in the drawing, which is in the middle of the moving platen and back platen, please keep it close to the moving platen if possible. Adjust the level pad until the air bubble is in the middle. Then put the Gradienter in the opposite cross way and adjust the level pad on the same side until the air bubble is in the middle position.

5. 5. Turn the Gradienter 90° and put it on the frame steel tape or tie bar, adjusting the level pad until the air bubble is in the middle position. Repeat these steps a few times until: Across level ≤0.16mm/m and longitudinal level ≤0.20mm/m.

6. 6. After the level is checked by the Gradienter, pour concrete into the foundation hole to fix the foundation bolt.

7. 7. After a period (about 10 days in summer, 15 days in winter) to take good care of the machine and ensure the concrete solidifies, repeat step 5 to adjust the leveling tolerance of the machine. Tie the foundation bolt to fix the machine after checking by the Gradienter.

4.2.1.2 Leveling tolerance for big machine (normally for clamping force more than 1800Ton)

Owing to the weight of the big machine, which will crush the leveling pads, we usually use armor plates instead of leveling pads. The adjustment steps for the big machine are the same as for the medium machine. NOTE! Make sure the concrete is hard before twisting the nut for the foundation bolt. The machine must be rechecked and adjusted after running for one month.

4.2.2 Adjust the nozzle center

Please adjust the concentricity of the nozzle with the mould by yourself as follows:

For large machines, adjusting the nozzle center relies on the slider set. Bolts A and B are used for adjusting the height for the nozzle. The left and right adjusting devices are used for adjusting the nozzle's left and right positions.

1. 1. Prepare a Vernier Caliper.

2. 2. Please adjust the machine leveling before adjusting the nozzle center.

3. 3. As shown in drawing a, loosen the fixed bolts that secure the injection unit base to the frame.

4. 4. As shown in drawing b, measure L1, L2, L3, L4 separately. Adjust horizontal bolts so that L1=L3, and adjust the up/down bolts on the base so that L2=L4. The tolerances are as per the following table.

5. 5. Fix the bolts and locknuts after adjustment.

5.3.1 Manual

Select the manual key on the panel, and then push the action button to operate each action. In this mode, each action can run separately.

5.3.2 Semi-automatic

Push the key for semi-automatic, and the machine goes into semi-automatic running. In this mode, close the safety door, mould closes, and the nozzle moves forward under high pressure, then other actions will proceed step by step until the product is ejected by the eject pins. At this moment, the operator opens the door, takes out the product, then closes the door and the next cycle will start. Or press "RECICLE" or "MOULD CLOSE" and the next cycle will start.

5.3.3 Automatic by magic eye

Push the key for automatic by magic eye or select the model for this in the controller, the machine will turn to this model. After the product is ejected by ejector pins and inspected by a magic eye in the hopper, the mould will close. Otherwise, the mould won't close and gives an alarm.

5.3.4 Automatic by time

Push the key for automatic by time or select the model for this in the controller, the machine will turn to this model. After ejector pins eject the product, the machine will continue to the next cycle some time later. * Please see the details in the controller operation manual.

6.6.1 Preparation before install mould

• 1) Make sure the products, size, and weight are suitable to produce before installation. Notice: Due to different densities, the injection weight is also different.

• 2) Measure the length/width/height, comparing with the distance between tie bars, max or min mould height, to judge if the mould can be installed in the machine.

• 3) Measure the outside size of the location ring for the mould, so that it can be matched with the hole in the fixed platen.

• 4) Check the mould spray sphere-diameter, depth, and hole diameter. Assuring all are matched with the machine.

• 5) Measure the size for the ejector hole and ejector platen, which should be suitable for the machine. Notice: The mould dimensions shall not exceed the size of the platen, otherwise personal injury will probably occur.

6.6.2 Step for install mould

1. 1

   1) Prepare the mould clamp, bolts, washers, spring washers, cooling water, and so on; some moulds need pipes for air blast and hoses for core pulling.

2. 2

   2) Power on, set the distance for mould opening according to the space required for the falling products.

3. 3

   3) Set the ejector stroke and ejector function according to the mould parameters and product size.

4. 4

   4) Power on the pump, press the mould adjust key, and the machine goes into mould adjusting status.

5. 5

   5) Adjust the mould thickness according to the actual size of the mould.

6. 6

   6) Open the mould, bringing the mould to the set position.

7. 7

   7) Ejector advanced, adjust the ejector pin number according to the mould request.

8. 8

   8) Move the carriage back.

9. 9

   9) Turn off the pump motor.

10. 10

    10) Hang on the mould (please make sure the two parts of the mould do not separate), put it into the platen (no collision with tie bar or machine), set the location ring into the installation hole in the fixed platen.

11. 11

    11) Use mould clamps, nuts, pads, washers, and spring washers to tighten the mould on the fixed platen. (No need for too much force). Notice: the depth for the bolt should be 1.5 to 1.8 times into the hole.

12. 12

    12) Power on the pump motor, press the mould adjusting key, and the machine runs into adjusting status.

13. 13

    13) Close the mould by manual, making the moving platen touch the mould gradually.

14. 14

    14) Power off the motor.

15. 15

    15) Tighten the clamp bolts, locking the mould. Notice: the mould should be locked steadily. Observe the length of the nozzle and the depth for the mould entrance. Otherwise, the nozzle or heating band will be destroyed.

16. 16

    16) Remove the ropes for hanging the mould.

17. 17

    17) Set the position, pressure, and speed for mould opening and closing, especially for the products requiring high-pressure clamping force. Notice: If the products can be produced perfectly, do not set the clamping force too high. It's better for the machine's life.

18. 18

    18) Power on the pump motor.

19. 19

    19) Open the mould to the end.

20. 20

    20) Close the safety door, pressing the mould adjusting key, entering into the automatic mould adjusting status.

21. 21

    21) Open and close the safety door, the machine will be in automatic adjusting status, once the mould is adjusted, the machine will change to manual automatically.

22. 22

    22) Observe the system pressure by the pressure meter to check if the clamping force is acceptable.

23. 23

    23) Press the mould close key to close the mould then power off the pump motor.

24. 24

    24) Tie all bolts and nuts for the mould clamp.

25. 25

    25) Connect the other parts, such as the cooling pipes. The step for mould installation is finished.

6.6.3 The Requirements for Mould Parallelism

The dimensional accuracy of the injection mould part, the loading, and the mould's function in especially complex tooling (multi-plate mould, sliding split mould), are heavily dependent upon the parallelism of the mould mounting platens. The degree of parallelism required by EUROMAP 9 will be achieved if the specified mould weights are not exceeded (as in the table above).

6.6.4 The T slot platen and thread hole platen

TEDERIC has T slot and thread hole platens according to the customer's requirements and products. So there are 2 different models of clamps. Notice: Bolt depth should be more than 1.5 times the thread hole size. For example, if the size for the clamping platen is M24, the depth for the bolt into the platen should be more than 36 mm with a strong bolt.

6.6.5 Changing Mould

• 6.6.5.1 Notice: the ball radius for the nozzle should be less than the one for mould entrance, or it will be leaked. Picture (A) is correct, the r < R, the nozzle bore < spray hole. Picture (B) is incorrect, as r>R, Nozzle bore > spray hole.

• 6.6.5.2 To remove the nozzle, use the correct tool. Slipping will damage the operator and/or the nozzle.

• 6.6.5.3 Be sure to apply high-temperature grease on the thread.

• 6.6.5.4 The nozzle, adaptor, barrel, and bolts only use the appointed elements of TEDERIC.

• 6.6.5.5 The melt temperature of normal plastic materials shown in the manual; The Barrel temperature must not exceed 350°C.

• 6.6.5.6 The nozzle center shall be adjusted in one line once the new mould is installed. Bolt A for adjusting the nozzle center right and left. Bolt B and C for adjusting the nozzle center up and down. The pin is for swiveling the barrel for screw change or removal.

• 6.6.5.7 For large machines, the adjusting for nozzle center is up to the slider set. Bolts A and B are used for adjusting the height for the nozzle. Left and Right adjust devices are used for adjusting the nozzle's left and right positions.

6.7.1 Attention before Injection

• 1) In order to protect the screw, it should be operated 15 to 30 minutes after the barrel temperature reaches the set value.

• 2) To prevent the destruction of the screw, the speed shall be under 60 rpm when there is no material in the barrel.

• 3) Do not get near the nozzle with hand or face, and it's forbidden to touch the barrel cover.

• 4) The mould should be made sure to be correctly installed before injection.

6.7.2 Oil Temperature

The best temperature for hydraulic oil is 40~46°C. If it's lower than 40°C or higher than 55°C, it's not good for products. Preheating is necessary if the temperature is lower than 40°C. Power on the motor without material, or set a certain pressure and flow, core advance and back, to quickly increase the oil temperature.

6.7.3 Injection Step

1. 1

   1) Setting barrel temperature according to the raw material and products, proceed to the next step 15 minutes after the plastic temperature reaches the setting value.

2. 2

   2) Open the hopper, put in the raw material, and close the hopper. (If there is an auto-loader or dryer, please follow the operation manual for loader and dryer).

3. 3

   3) Setting properly the position, pressure, speed, and back pressure for charge according to the products weight, proportion for raw material, and total injection weight; meanwhile, the related parameters for injection and keeping pressure shall be set well. There are two models for back pressure when charging, manual or proportion, customer should choose and inform TEDERIC. Each pressure will be shown in the pressure meter, with obvious instructions. Notice: Big back pressure will add to consumption energy.

4. 4

   4) Press motor on key, power on the motor.

5. 5

   5) Press mould close key to close mould.

6. 6

   6) Press nozzle advance key, keeping the nozzle in conformity with the runner for mould. Notice: steps 5 and 6 may be different according to different material and mould.

7. 7

   7) Press charge key, making the screw move to set position, charge is stopped; during charge period, if you want to stop the charge please press the charge key again.

8. 8

   8) Press injection key, make the injection and hold on.

9. 9

   9) When hold on finishes, press charge key for the next cycle of charge.

10. 10

    10) After completion of charge and cooling, press open mould key to open mould.

11. 11

    11) Eject after completion of mould opening, open the safety door and fetch out the products.

12. 12

    12) Observe the products to adjust related parameters accordingly.

13. 13

    13) Repeat above steps and readjust parameters to produce qualified products.

14. 14

    14) Confirm the product quality achieves request, press semi-automatic or full automatic key to enter into automatic working status.

7.3.1 Lubrication system components and features

The lubrication system consists of a pump, pipe, distributor, and lubrication points (nipple). The lubrication oil goes from the pump to a variety of distributors to the lubrication points, to achieve lubrication for the moving parts. The lubrication system is controlled by the computer. The controller monitors the system condition by display. In the lubrication process, if the oil tank is too low, oil leaks, oil filter gets blocked, or oil pressure is not enough, the controller will alarm. Please check the reasons for poor lubrication. Add lubricants or repair in time to ensure the normal running of the injection moulding machine.

7.3.2 Principles of lubrication

7.3.2.1 The principles of determined resistance of the lubrication system

There are damping lubrication distributors in the system. When the lubrication pump is running, there is a certain pressure as damping, and when oil pressure is higher than the damping pressure difference, the oil will overcome the damp to all points. As the damping hole can be big or small, this system ensures the lubrication oil value meets the request for each point. If during the lubrication time the pressure does not achieve the setting value, the controller will alarm to inform of a problem in the lubrication system.

7.3.2.2 The principle of quantitative pressure-type lubrication system

Quantitative lubrication configuration: when the pump works, pressure oil comes to the distributor, and after a setting time, the pump unloads automatically. The spring in the quantitative distributor presses oil to the lubrication point. As the cavity size of the distributor can be chosen, each point's oil value can be controlled, not too much or less. As the pump will run and unload and the controller will monitor, during the working period if point pressure does not reach the pressure switch setting value, the controller will alarm to inform of a problem in this system. The quantitative pressure-type lubrication system has 2 different models: with or without an indicating bar.

7.3.3 Notice

• 1. The lubrication oil that is polluted by water, steam, dust, and sunlight is not allowed to be used.

• 2. During machine running, must observe all lubrication points to ensure they are in normal condition.

7.3.4 Maintain for Lubrication System

TEDERIC'S machine is equipped with center lubrication for the clamping toggle, toggle pin, bush, and rear tie bar nuts. The lubrication pump motor is a three-phase electric motor. It should be ensured that the lubrication pump motor rotates in the right direction. When the lubrication pump is working, looking from the top of the motor, it should be rotating clockwise, otherwise there is no pressure, then you should exchange 2 cable positions of the three-phase. Note: Filter removal or filter core removal is not allowed! There is a pressure switch on the far end of the lubrication system. It is used to ensure all points have enough oil. When the lubricate system is working, if the lubricants do not reach the far end, or arrive but with not enough pressure, the pressure switch will give the signal to the controller and alarm.

• 7.3.4.1 Regularly observe the working conditions of the lubrication system and ensure the lubrication time is enough. Lubrication dates should be set reasonably, such as lubrication cycle and lubrication time.

• 7.3.4.2 Maintain the oil tank at a reasonable bit of oil. If found in non-performing lubrication, should be lubricated, and check the status of lubrication points, lubrication, and ensure good lubrication for the machine.

7.3.5 The lubrication between the bush of the moving platen and the bar

There are four grease nipples on the moving platen. A grease gun must be regularly used to meet the requirements to get the grease inside.

7.4.1 Construction cooler

The heat exchange consists of the cover, tube plate, tube, heat pipe, baffle, sealing gaskets, and tripod, etc., as per Fig. The space between the heat transfer tubes and shell is called SHELL SPACE. The space inside the tube is called TUBE SPACE. The hot shell-space fluid and cool tube-space fluid become heat exchanged through the heat exchange tube, so that the oil temperature drops down.

7.4.2 The use of heat exchanger.

Notice: when used, the pressure and temperature should not exceed the values on the nameplate and "Product Certification". In addition to special order products, only use fresh water for the cooling medium. Fresh water requirements are in the following table:

7.4.3 Test, maintenance and cleaning of the heat exchange

7.4.3.1 Test of the heat exchange

Reference the structural drawing of heat exchange, open the cover and check for:

In order to facilitate the detection, the best way is for the heat exchanger to be removed from the machine. You should often check the status of equipment and determine the actual situation for the detection time. For city water supply, check about every six months. For industrial water and groundwater, or water containing a lot of salt, check about once a month.

• 1) Check the inside of the copper tube for no water dirt and corrosion.

• 2) Check whether all seals are in good condition.

• 3) The outer surface of heat pipe, shell inside surface, as well as others in contact with the oil, to see whether or not there are stolen properties and impurities, or if it has corrosion.

7.4.3.2 The maintenance of the cooler

If the machine is not in use for a long time, please let fluid out from the heat exchanger; also if the heat exchange stops working, the fluid may freeze, so please let the fluid out. Common failure and the treatment of the failure:

7.4.3.3 Cleaning the heat exchanger

If the cooling effect falls down, then the heat exchange may need cleaning. Covers at both ends should be removed to check whether there is anything of dirt or corrosion. At least every six months, clear the heat exchanger. Use commercially available alkaline cleaning liquid, cleaning the main housing and the heat transfer tube. For intractable interlayer dirt, weak hydrochloric acid can be used for cleaning, washing the main and heat transfer parts with running water. For more heat transfer tubes with inner scale, use cleaning agents to dissolve and immerse the scale, and then use water and suitable washing brushes. Note: Do not leave the cleaning agent inside the heat exchanger. Before re-assembly, the heat exchanger must be cleared of chemical substances with water, and then dried with compressed air.

7.5.1 The oil filter on the machine

An oil filter is installed on the fuel tank side at the entrance of the hydraulic oil to keep it clean. When performing replacement or repairing/cleaning the filter system, rotate the filter cover open (at this time it will automatically turn off the self-styled valve to isolate the tank circuit, so the oil in the tank will not outflow), and pull out the filter core to replace or clean it. Some of the oil filters are installed in the oil tank inside the tube, making it easy to remove and clean. Some machines may also be equipped with high-pressure bypass filters (for variable displacement pump as a standard configuration) or return oil filters. Start by rotating the cover, then take out the core for cleaning or replacement. The hydraulic system filters are a powerful guarantee for normal machine operation. They must be regularly checked, and depending on the oil condition, determine whether cleaning or replacement of filters, or even replacement of hydraulic oil, is needed. Some machines are fitted with a filter alarm, which uses the hydraulic oil flow through the pressure filter. If a clogged filter causes too much pressure on the pressure gauge, causing the pointer to go to red, or the machine has a filter warning, the filter devices need to be cleaned or replaced.

7.5.2 Cleaning

With light oil, gasoline, or oil, do a thorough washing to remove all obstructions and dirt around the filter core, and at the same time remove all metal objects on the middle bar.

7.5.3 Notice

• 1) When the oil filter is apart, pump start is not allowed.

• 2) When using compressed air blowing, the air must be clear and dry.

• 3) If there is damage to the filter core, a new filter core must be replaced.

• 4) When replacing a new core, care must be taken not to damage it.

• 5) After changing a new core and preparing to start the machine, we must check whether the caps are tightened.

• 6) After installing the filter, the pump should be run no-load for 10 minutes. The machine can be run only without any unusual behavior.

7.5.4 Change the hydraulic oil

Note: Used oil and filters must be properly disposed of to avoid environmental pollution. You must use the recommended grade of hydraulic oil from qualified sources. When replacing with new oil, it is important to empty the tank in advance, leaving no old oil, including in all pipes and the heat exchange. At the same time, a new oil filter should be assembled.

7.10.1 Adjustment of Big Machine's Hydraulic Support Sliding Pad

On the DH680 - DH4500 large and medium-sized machines, under the moving platen support, a hydraulic slip foot system is used (see figure below). The 2 groups of slip feet use pressure to support the moving platen, reducing the bending moment to a minimum to ensure the tie bar is always level and improve the performance of the clamping system. The slip feet are auxiliary devices used to support the moving platen to ensure the four tie bars do not bend. If this device is adjusted too tight, it will cause mould adjusting difficulties, and too loose cannot protect the tie bar from bending under a heavy mould. Before the machines are shipped, this device has been adjusted to good condition, so new machines do not need adjusting. But after a period of running, the machine must be checked for looseness and, if necessary, adjusted. It is necessary to keep suitable support pressure and accumulator pressure. Its structure and principle are in the following plans:

7.10.1.1 Adjustment of support pressure

Adjust the pressure switch to get the slide foot pressure, normally 2~6 Mpa is the pressure range, adjusting the pressure based on the mould weight. The pressure switch and relief valve are assembled on the opposite side of the moving platen, and the pressure meter is on the front side of the moving platen. Turn the handle clockwise to raise support pressure and anticlockwise to reduce support pressure. If the pressure is too high, turn the handle of the pressure switch anticlockwise and loosen the handle on the relief valve, let the pressure out, and then set the valve and pressure switch. This pressure has been adjusted well in the factory. Under no special condition, please do not adjust it wantonly. Describe the elements of the hydraulic support system: (1) Accumulator: Pressure inside the accumulator is used to support the slide foot cylinder and support the moving platen. (2) Direct valve: The role is to change the oil direction. If the pressure is not enough, the pump will input oil to the accumulator through the valve. When the accumulator pressure achieves the setting value of the pressure switch, the valve changes the core position and the accumulator offers pressure to support the cylinder. (3) Relief valve: it is for limiting the maximum pressure of the accumulator, protecting the system from too high pressure and ensuring safety. (4) Pressure switches: used to determine the hydraulic pressure on the fluid-filled pressure accumulator size. Hydrostatic support description: hydraulic pump provides pressure to the accumulator, accumulator offers oil to the support cylinder of the slide foot. An Allen key is used to adjust the pressure switch; clockwise to raise the fluid-filled pressure and anticlockwise to reduce the fluid-filled pressure to the accumulator. Hydrostatic pressure can be read on the pressure meter on the moving platen. The relief valve protects the hydraulic system. Normally the relief valve pressure is a little higher than the pressure switch by 2 ~ 3 bar, and the maximum should not exceed 140 bar. Check the gap of the tie bar with the brass bush; it should be the same up and down, which means the hydraulic support adjustment is OK.

7.10.1.2 Pneumatic accumulator

Note: For prevent explosions, accumulator filling requests for more than 99.995% purity Nitrogen. Strictly prohibit the use of other gases. When inflated, release the relief valve adjustment handle, and then the big accumulator top lid. Fitted with pneumatic tools and high-pressure nitrogen gas connections, slowly open the instrument switch to inflate, up to the required pressure (the machine is for 2 - 3Mpa). When the pressure is too high, the screw plug to open the exhaust so that the provisions of the value of reduced air pressure. In the use of the process should be regularly checked the inflation pressure gas storage. Less than or exceeding the inflation pressure will influence the moving platen.

7.10.2 Adjustment of Moving Platen Sliding Pad for two platen

Moving platen slide support device of a two-platen machine is used to support the moving platen and adjust the moving platen center and the front platen center accordingly. In order to ensure the installation of the mould on the moving platen can be smoothly opening mould and closing mould, also finishing the half-nut lock and hold pressure. This device about the adjusting plate shall not transfer too tightly; if so, it will increase the load of opening mould and closing mould, causing mould opening resistance to be too large; shall not transfer too loose which makes the left and right guide gap too large, resulting in the moving platen swinging left and right. Before shipment, we will adjust this device in the best position, so the new machine does not need to be adjusted, but after working a period of time, it must be checked for loosening, if so, then adjust it as required. Before adjustment, it must adjust the machine clamping unit of moving guide rail well, then remove the mould, and put on the center of tooling. Under the mould adjustment condition, pressing the clamping button will move the moving platen mould tooling sleeve and the front platen on the fixed mould tooling sleeve tightly. After that, first visual the tooling set to see whether it is offset. According to the offset direction (U/D/L/R), use the corresponding adjusting screw; using an inside micrometer measuring parallelism between the moving platen and the front platen. Then according to the measurement results, adjusting the screw until the corresponding parallelism and to the center is in a reasonable range. Then press the mould opening and closing button, check whether the system pressure and action under mould opening and closing is smooth. After adjusting properly, install the mould to test it until achieving satisfactory results.

8.1.1 Finished product is not complete

8.1.2 Shrinking

8.1.3 Products adhere to mould

8.1.4 Sprue Adhere to Mould

8.1.5 Flash

8.1.6 Products Break when Mould Open or Eject

8.1.7 Combination of Line

8.1.8 Flow Lines

8.1.9 Silver line and gas scar

8.1.10 Finished Surface is not Shiny

8.1.11 Deformation product

8.1.12 Gas Pores is inside

8.1.13 Black Port

8.1.14 Black Line

8.1.15 Stable Produce Cycle Time

Most of the above problems are caused by produce cycle time stability. As any plastic material melts in the barrel or the mould temperature keeps a stable temperature, the heat must balance. During produce, the material in the barrel gets the heat from the heat band and friction of the screw with the barrel, so it is important to keep a balance of heat coming into and out of the barrel and mould. So you must keep a constant produce cycle time. If the cycle time is too short, the heat is not enough to melt the plastic material, and in the mould, the heat will increase also.

8.1.16 Used Material

It must be controlled that the hardness of used material must be the same as new. It is better that used material will be crushed and dried immediately, not stored long time. The size of used material granules should be the same as a new one. If the plastic material is used many times it will reduce the material property. If the products request special properties, it is better not to use the used material.

8.1.17 Screw Slip (The Material cannot come to barrel)

8.1.18 Melt Material Flow from the Nozzle

8.3.1 Few points should be thinking

• 1) Screw: The different plastic materials need different screw constructs, it not only influences produce value but also the quality and property. So before deciding, should tell what kind of plastic material to be used, TEDERIC will give you a suitable machine.

• 2) Injection Value: Calculate the product's total weight (Single piece weight times cavity number), so the injection weight must be more than it 15~20%. Please note, in the TEDERIC catalogue we list the "Theoretical shot volume". So the user should know the plastic material density, then calculate and get the correct weight.

• 3) Injection Pressure: Each injection unit can match 3 different dimension screws. A small screw diameter is with high injection pressure and a big diameter screw is with low injection pressure. If the user product is with a thin wall, that means it needs high injection pressure. Notice: For an injection unit, if the injection pressure is high, the injection weight will be low, and if the injection pressure is low, that means the screw diameter is big so the injection weight is also big.

• 4) Mould size: The mould size depends on the product size, cavity number, and cooling water system of the mould etc. So the mould size should not be more than the "distance between tie bar", but if the mould is too big or too small it is not good for machine life. See manual concerning chapter.

• 5) Core and air blast: Some moulds need a core pulling function and air blast valve one or two groups, even more, please mention to TEDERIC.

8.3.2 TEDERIC machine model

TEDERIC produces different series of injection moulding machines and names them different as follows: Prime code of clamping unit: T: Hydraulic toggle type three-platen clamping structure (For T omit), H: Hydraulic locking two-platen clamping structure, E: Electric toggle type three-platen clamping structure. Prime code of injection unit: Double-cylinder injection reciprocating screw structure, M: Single-cylinder injection reciprocating screw structure, J: Extruded injection structure (In the low pressure series), J: Extruded injection structure (In the high pressure series), E: Electric injection structure. TEDERIC can design for your special requests. TEDERIC-- Solutions Provider for Global Plastic Industries. Rev: V2.0