1.3.1 Mechanical Hazards

1.3.2 High-Pressure Leakage Hazards

1.3.3 High-Temperature Scalding Hazards

1.3.4 Explosion Hazards

1.3.5 Electrical Hazards

The injection molding machine utilizes high-voltage and large-current power. Power requirements are listed on the electrical nameplate on the machine frame and in the electrical drawings. Ensure the equipment is connected properly according to the circuit diagrams and complies with all local electrical regulations.

1.3.6 Noise Hazards

Under normal operating conditions, the machine's noise emissions will not cause harm. However, prolonged exposure to excessive noise can damage hearing. Ensure that workplace noise levels comply with local laws, and wear hearing protection equipment during operation.

1.3.7 Gas, Steam, and Dust Emissions

Some materials emit harmful gases, steam, or dust when processed. Please install an exhaust/ventilation system in accordance with local environmental and safety regulations.

1.3.8 Slip, Trip, or Fall Hazards

Walking, standing, climbing, or sitting on the machine is strictly prohibited. Use certified platforms or ladders to reach elevated areas.

1.3.9 Hoisting Hazards

When hoisting the machine or its components, it is critical to use appropriate lifting equipment, apply proper balancing techniques, and use the designated lifting points. Please refer to the installation details in this manual. Overloading the lifting equipment is strictly prohibited.

Safety Production Regulations

• Operators must wear the designated safety uniform!

  

• Operators must wear safety masks/goggles!

  

• No smoking or open flames are permitted in the workshop!

  

• Do not leave miscellaneous tools or goods around the machine!

  

• Keep the windows of the safety guard doors clean and clear!

  

• Only a qualified, licensed operator should install and adjust the mold. Close attention must be paid to the mold's weight and the lifting equipment used!

  

• Ensure the safety guard is completely closed when the machine is running!

  

• Prevent any metal objects from dropping into the hopper and barrel—this will severely damage the screw and barrel!

  

• Before removing any hydraulic elements, switch off the motor power and ensure there is zero pressure in the hydraulic system!

  

• Switch off the main power switch before checking electrical circuits or opening the electrical cabinet door!

  

• The mold area can reach high temperatures. Use personal protection when entering this area. High-temperature molds must be marked with a burn hazard warning label!

  

• If an unexpected issue occurs during automatic operation, residual pressure may remain in the barrel and mold. Before troubleshooting, perform necessary pressure relief operations (such as decompression/suck-back). Next, move the carriage backward to separate the nozzle from the mold. Only after safety is confirmed may the safety door be opened to enter the mold area.

  

• If the machine will be stopped for an extended period, switch off the main power switch!

  

• Do not alter the electronic or hydraulic systems without prior approval from Tederic Machinery Manufacture (China) Co., Ltd.!

  

Safety Distances & Machine Interactions

• Maintain a safe distance between your body and any moving parts.

  

• Do not touch moving machine parts!

  

• Moving Part of Machine / Products fall down chute

  

• When the machine is running, never place your hands or any body part inside the machine. This will cause serious injury.

  

• Attention! Never put your hands or fingers into the feed hopper at any time—serious injury will occur.

  

• Do not remove safety labels.

  

• Serious attention: Do not touch the barrel cover, as temperatures may be extremely high.

  

• Do not place items on the barrel cover!

  

• If you must remove the barrel cover for maintenance, you must disconnect the power first.

  

• A clamping unit linkage mechanism that is not fully locked stores kinetic energy; this can cause the platen to move unexpectedly. To prevent this, perform an opening action to confirm the mold is fully open before opening the safety door.

  

• If the machine allows manual ejection or core pulling (neutron) while the safety door is open, it is strictly forbidden to alter the internal machine parameters. You must ensure the ejection and core pulling speed is ≤10mm/s while the button is held.

  

• Operators and maintenance personnel must enter the work area only through designated locations. It is the user's responsibility to keep the ground, access passages, and working locations clean and free of trip hazards.

1.6.1 Safety Covers and Safety Doors

1.6.1.1 Protective function

• A. Keeps personnel and objects away from dangerous areas.

• B. Prevents molten plastic from splashing outward.

• C. When the door opens, the safety devices will immediately halt any dangerous mechanical actions.

1.6.1.2 Mold area safety door

There are movable doors on each side of the mold setting area, and a movable upper cover on the top (medium and large machines do not have an upper cover). Ensure the moving doors and upper covers are fully closed after fixing the mold. Notice: You should only move the upper cover when installing a robot.

1.6.1.3 Nozzle cover

To prevent the danger of high-temperature molten plastic splashing, a nozzle cover is equipped over the nozzle area.

1.6.2 Mechanical Safety Device

The mechanical safety device is critical for protecting the operator and the mold. Principle: When the safety door is opened, a physical drop-shield (or drop-bar) falls into place to block the safety rod, preventing the machine from clamping. You must confirm this device works perfectly. Do not disassemble it. Notice: Regularly check and adjust this device. Ensure that when the safety door is opened, the shield falls freely to block the hole. Test it multiple times after adjustment. When the safety door is closed, ensure there is a clearance of 3 to 5 mm between the bottom of the safety bar and the shield to avoid unnecessary tension.

1.6.3 Electrical Safety Devices

Electrical safety devices include the air switch, circuit breakers, grounding line (earth), emergency stop switches, and limit switches on the safety doors. Machines feature clear grounding connection marks to remind users. Emergency stop buttons are located on the operation panel and on the protective board of the non-operating side (fixed platen). Pressing this button stops all actions immediately, including the pump motor (though barrel heating remains on). All auxiliary equipment connected to standard interfaces will also shut down. The screen will display 'Manually open stop button.' To restart the machine, twist the button clockwise to release it. The front safety door features two limit switches; the rear door features one or two. They are interlocked. If the front door is opened roughly 50mm, the machine will not clamp. If the rear door is opened more than 20mm, the machine will not clamp. (On some models, opening the door cuts power to the pump motor). On some machines, a limit switch is installed on the nozzle cover. Opening the nozzle cover triggers the switch, preventing 'Injection,' 'Charge,' and 'Nozzle Move' actions, and interrupting semi-automatic or fully automatic modes. Notice: If the mold area is equipped with a light curtain, safety pedal, or safety mat, triggering it will prevent mold opening and closing. Movement is only permitted after the hazard is removed and safety is confirmed. Notice: You must check the reliability of all limit switches and emergency stop switches daily. Any failed or damaged switch must be replaced immediately.

1.6.4 Hydraulic Safety Device

• A. Safety door hydraulic protective valve (cam valve): When the front safety door is opened, the clamping hydraulic circuit is physically cut off by the cam valve, stopping any clamping action.

• B. System safety valve: The manufacturer sets a maximum allowable system pressure and seals the valve. If pressure exceeds this set value, the safety valve opens, limiting the pressure to protect operators and hydraulic components (pumps, pipes, etc.).

1.6.5 Feed Platform

TEDERIC highly recommends using an autoloader to feed material into the hopper or hopper dryer. If manual feeding is required, a platform compliant with EN ISO 14122 standards must be used. TEDERIC can assist in designing or providing this feeding platform upon request. Notice: Even when using a feed platform, operators must remain vigilant against slipping or falling injuries.

3.2.1 Preparation

• A. Before lifting, ensure the moving platen is adjusted to the minimum mold height position.

• B. Prepare the crane or lifting equipment, hooks, straps, or wire ropes. (Check the technical parameter table for the machine's exact weight).

• C. Prepare wooden blocks or heavy padding cloths to protect the machine's paint.

• D. Ensure a solid, smooth, and level concrete foundation is ready.

3.2.2 Lifting Notices

• A. Slings/straps must not bear weight on fragile machine parts (such as sheet metal covers). Follow the provided lifting sketches strictly.

• B. Lifting and installation must be performed by certified, skilled riggers.

• C. The machine may only be lifted and moved horizontally using the designated lifting points. It is crucial to prevent the slings from slipping!

• D. No personnel are allowed to stand or linger beneath a suspended load.

3.2.3 Lifting Sketch for Small Machines (Single-Piece Frame)

(Refer to diagrams).

3.2.4 Lifting Sketch for Medium Machines (Split Frame, rear lifting hook on the fixed platen)

Before lifting, ensure the rear portion of the tie bars is securely tied to the frame with solid wire, ensuring the molding platen and frame do not separate during lifting. (Refer to diagrams).

3.2.5 Lifting Sketch for Large Machines

For D-1500 machines and larger, the clamping unit, clamping frame, and injection unit are packed and shipped separately, and thus must be lifted separately. Safety doors and sheet metal covers are also packed separately.

3.3.1 Connecting the Machine

Small machines with unified frames do not require connection. Medium and large machines utilize a split-frame design. After hoisting and positioning the units, connect the injection unit to the clamping unit prior to further leveling and adjustment.

3.3.1.1 Connecting the Frame of Medium and Large Machines

Connection Steps: Based on the foundation layout drawing, place leveling pads or steel plates around the anchor bolt holes on the concrete foundation. Lower the clamping unit onto the pads/plates. Next, lift the injection unit into alignment. Ensure the mounting holes align correctly. Insert the frame bolts, add washers and nuts, and hand-tighten. Perform an initial leveling and ensure nozzle alignment is correct before fully torquing the bolts and reinstalling the partitions/covers.

3.3.2 Machine Cleaning

The machine will accumulate dirt and dust during shipment and installation. Many exposed metallic surfaces are coated with an anti-rust agent prior to shipping. This must be cleaned off after positioning the machine. Notice: Do not use harsh chemical solvents to remove the anti-rust coating or dirt. Pay special attention to cleaning dirt from piston rods, guide bars, and tie bars to prevent damage to the oil seals.

4.2.1 Adjusting Leveling Tolerance

4.2.1.1 Leveling Small Machines (Unified Frame)

1. 1. Adjust the machine to the minimum mold height. Place leveling pads under the frame's designated mounting holes.

2. 2. Place a precision machinist's spirit level across the machine frame between the moving platen and the stationary (fixed) platen.

3. 3. Adjust the leveling pads until the bubble is centered. Move the level to the opposite side and repeat.

4. 4. Rotate the level 90° (longitudinally) and place it on the frame rails or tie bars. Adjust pads until the bubble is centered.

5. 5. Repeat these steps iteratively until the tolerances are met: Transverse level ≤ 0.16 mm/m; Longitudinal level ≤ 0.20 mm/m.

4.2.1.2 Leveling Medium and Large Machines (Split Frame)

1. 1. Clean the foundation. Place leveling pads according to the foundation diagram. Lift the unit so it is suspended ~500mm above the ground. Insert anchor bolts upward through the frame holes, adding flat washers, spring washers, and nuts (leave 5–10mm of thread exposed above the nut).

2. 2. Lower the machine onto the pads, ensuring anchor bolts drop into the foundation holes. Connect the injection and clamping units as described in Section 3.3.1.

3. 3. Ensure the machine is at the minimum mold height.

4. 4. Place the precision level transversally across the frame between the moving and fixed platens.

5. 5. Adjust the pads until the transverse and longitudinal tolerances are met (≤ 0.16 mm/m transverse; ≤ 0.20 mm/m longitudinal).

6. 6. Once leveled, pour concrete/grout into the foundation anchor holes to secure the bolts.

7. 7. Allow the concrete to cure (roughly 10 days in summer, 15 days in winter). Once cured, repeat Step 5 to verify the level, then fully tighten the anchor nuts.

4.2.1.3 Leveling Extra-Large Machines (Clamping Force > 1000 Tons)

Because the extreme weight of these machines will crush standard leveling pads, heavy-duty steel plates are used instead. The adjustment steps remain identical to those for medium machines. Notice: Ensure the concrete is completely cured before torquing the anchor nuts. The machine's level must be rechecked and readjusted after its first month of operation.

4.2.2 Adjusting Nozzle Concentricity

1. 1. Use a Vernier caliper to take measurements.

2. 2. Ensure the machine frame is perfectly level before adjusting the nozzle.

3. 3. Loosen the fixing bolts connecting the injection unit base to the main frame.

4. 4. Measure clearances (L1, L2, L3, L4). Adjust the horizontal positioning bolts until L1 = L3. Adjust the vertical elevation bolts until L2 = L4. (Refer to the tolerance table in the technical manual).

5. 5. Once aligned, tighten all fixing bolts and locknuts.

6.6.1 Pre-Installation Checks

• 1. Verify the mold size fits between the machine's tie bars.

• 2. Verify the mold's closed height falls within the machine's Min/Max mold height specifications.

• 3. Measure the mold's locating ring and ensure it matches the hole in the stationary platen.

• 4. Check that the nozzle's spherical radius and orifice diameter match the mold sprue bushing.

• 5. Verify the ejector pin layout aligns with the machine's ejector platen.

6.6.2 Mold Installation Steps

1. 1. Prepare mold clamps, T-bolts, washers, nuts, and cooling water hoses.

2. 2. Turn on the motor and adjust the moving platen to a wide enough position.

3. 3. Set the ejector pins to the fully retracted (zero) position.

4. 4. Move the injection carriage fully backward.

5. 5. Turn off the pump motor.

6. 6. Using proper lifting straps, hoist the mold down between the platens. (Ensure both halves of the mold are bolted together). Guide the locating ring into the stationary platen hole.

7. 7. Lightly secure the mold to the fixed platen using clamps and bolts. Notice: Ensure the bolts thread into the platen holes to a depth of at least 1.5 to 1.8 times the bolt's diameter.

8. 8. Turn on the pump motor. Select the 'Mold Adjust' mode.

9. 9. Slowly close the moving platen until it firmly touches the rear of the mold.

10. 10. Turn off the motor.

11. 11. Securely tighten all clamps on both the fixed and moving platens.

12. 12. Remove the lifting straps.

13. 13. Turn on the motor. Open the mold slowly to verify smooth separation.

14. 14. Close the safety door and perform an automatic 'Mold Height Adjust' cycle (if equipped) to set the exact clamping tonnage.

15. 15. Set up cooling water lines and any core-pull hoses.

6.6.3 Mold Dimensions and Weight

Ensure the mold does not exceed the maximum weight capacity of the platens. Heavy molds can cause the moving platen to tilt or the tie bars to wear prematurely. When running small molds, the maximum clamping force must be reduced proportionately to prevent platen bowing.

6.6.4 Mold Parallelism Requirements

To achieve EUROMAP 9 parallelism standards and prevent damage to complex tooling, the mold weight must be distributed evenly, and clamping force must not exceed the structural limits of the platen.

6.6.5 T-Slot vs. Threaded Hole Platens

TEDERIC provides either T-slot or threaded-hole platens based on the order. Notice: For threaded platens (e.g., M24 threads), the high-tensile bolt must engage the threads to a depth of at least 36mm (1.5x diameter) to prevent thread stripping under pressure.

6.6.6 Changing the Nozzle

• Notice: The spherical radius (r) of the machine nozzle must be strictly smaller than the radius (R) of the mold sprue bushing. The orifice bore of the nozzle must also be slightly smaller than the sprue bore. If r > R, molten plastic will leak under high pressure.

• Use the correct wrenches to remove the nozzle to avoid injury or damage.

• Always apply high-temperature anti-seize grease to the threads before installing a nozzle.

• Adjust nozzle concentricity (up/down, left/right) using the adjustment bolts on the carriage base. Ensure the nozzle strikes the sprue bushing perfectly dead-center.

6.7.1 Pre-Injection Checks

• 1. Allow the barrel to soak at the set temperature for 15 to 30 minutes before rotating the screw to prevent snapping the screw tip.

• 2. If the barrel is empty of plastic, keep screw RPM below 60 to prevent metal-on-metal wear.

• 3. Never put your hands or face near the nozzle area.

6.7.2 Hydraulic Oil Temperature

The optimal hydraulic oil temperature is 40°C to 46°C. If the oil is below 40°C, cycle the machine dry (e.g., moving the carriage or cores back and forth) to warm the oil via system friction.

6.7.3 Step-by-Step Injection Setup

1. 1. Verify barrel temperatures. Fill the hopper with dried raw material.

2. 2. Set the charge (plasticizing) stroke, speed, and back pressure based on the target shot weight. Notice: Excessively high back pressure wastes energy and degrades the plastic.

3. 3. Start the motor, close the mold, and bring the carriage forward so the nozzle contacts the mold.

4. 4. Trigger the charge function to melt a shot of plastic.

5. 5. Trigger the injection function to push the plastic into the mold, followed by the hold-pressure stage.

6. 6. Allow the part to cool while the screw rotates to charge the next shot.

7. 7. Open the mold, eject the part, and inspect it.

8. 8. Adjust injection pressures, speeds, switch-over positions, and cooling times based on the quality of the molded part. Repeat until the product is defect-free, then switch to automatic mode.

7.3.1 System Components and Features

The system consists of a pump, tubing, distributors, and lubrication points. The computer monitors the system using a pressure switch. If oil is low, lines are leaking, or pressure is not met within the set time, the controller will trigger an alarm.

7.3.2 Principles of Lubrication

7.3.4 Maintain for Lubrication System Notices

• 1. Lubrication oil contaminated by water, dust, or sunlight must not be used.

  

• 2. Regularly observe the tie bars and toggle pins to ensure they possess a healthy film of oil.

• 3. Ensure the lubrication pump motor rotates clockwise.

• 4. If the oil filter is clogged, replace the filter element immediately. Never run the system without the filter element installed.

7.3.5 Moving Platen Bushings

There are standard grease nipples on the moving platen guides. A manual grease gun must be used periodically to inject heavy grease into these points.

7.4.1 Usage Notices

Only use clean, fresh water as the cooling medium unless special modifications were ordered. Pressures and temperatures must not exceed the limits stated on the nameplate.

7.4.2 Maintenance and Cleaning

1. 1

   If the cooling effect diminishes, the tubes are likely fouled with mineral scale or dirt.

2. 2

   1. Remove the end caps to inspect the copper tubes.

3. 3

   2. Clean the tubes every six months. Use a commercial alkaline cleaning solution or a weak hydrochloric acid solution for severe scale. Flush thoroughly with clean water afterward.

4. 4

   3. Notice: Ensure no cleaning chemicals remain inside. Dry with compressed air before reassembly.

5. 5

   4. If the machine is shut down during freezing weather, all water must be blown out of the heat exchanger to prevent ice from rupturing the tubes.

Disassembly

1. 1. Heat the barrel to processing temperature and purge all plastic.

2. 2. Move the carriage fully backward.

3. 3. Disconnect the carriage cylinders and swivel the injection unit outwards (approx. 20°) to create space.

4. 4. Unbolt the half-rings connecting the screw shank to the drive spindle.

5. 5. Remove the nozzle and barrel adapter.

6. 6. Push the screw forward out of the hot barrel.

7. 7. Notice: Viscous resins like PC or PVC will stick like glue if allowed to cool. Purge the barrel with PS or PE before shutdown to make screw removal easier. Use wooden blocks or brass tools to push the screw; never use hardened steel that could scratch the barrel.

Reassembly

1. 1. Ensure the screw slides smoothly into the barrel.

2. 2. Align the keyway on the screw shank with the drive spindle.

3. 3. Apply high-temperature anti-seize grease (e.g., MoS2) to the left-hand threads of the screw tip to ensure it can be removed in the future.

4. 4. When bolting the barrel adapter, tighten the 12.9-grade bolts evenly in a cross/diagonal pattern using a torque wrench.

7.10.1 Mechanical Sliding Shoes (Small Machines D80–D500)

Underneath the moving platen are mechanical sliding shoes that support the platen's weight, preventing the tie bars from bending. To adjust: Unclamp the mold, loosen the locking nuts, and adjust the support plate bolts until the shoes glide evenly on the machine rails without lifting the platen off the tie bars.

7.10.2 Hydraulic Support Shoes (Large Machines D650–D4000)

Large machines use hydraulic cylinders (shoes) under the moving platen to dynamically support the immense weight, keeping the tie bars perfectly level.

8.1.15 Stable Cycle Times

Maintaining a highly consistent cycle time is critical for thermal stability. If cycle times fluctuate, the residence time of the plastic in the barrel changes, destroying the heat balance and leading to inconsistent part quality.

8.1.16 Using Regrind Material

Regrind (used/crushed) material must be kept clean, dried properly, and ideally mixed at a consistent ratio with virgin material. Granule size should match the virgin material to prevent feeding issues.

8.1.17 Screw Slipping (Failure to Feed)

Usually caused by a feed throat that is too hot (bridging), insufficient back pressure, or a worn check ring.

8.1.18 Drooling from the Nozzle

Melt temperature too high or insufficient suck-back (decompression) stroke.

8.3.1 Selection Criteria

8.3.2 TEDERIC Machine Models

TEDERIC produces various series. Example nomenclature: