1.4.1 Icon signs

Danger

Personal injuries. Posing immediate threats. Death caused by serious injuries.

Warning

Personal injuries. Possible danger. Possible death or serious injuries.

Caution

Personal injuries. Minor danger. Mild trauma.

Information

Application prompts and other important/helpful information and prompts. No danger, or no consequence of personal injuries or property losses.

1.4.2 Machine signage

The injection moulding machine works under high pressure and strong power. It may pose dangers to personnel. The machine of the company has been equipped with corresponding safety devices to prevent personal accidents.

• Danger: High voltage. Exposure to a dangerous voltage may cause serious injuries or even death. Power supply should be cut off before any operation is started in a strong current area. Electrical work may only be conducted by trained professionals.

  

• Warning: High-temperature surface. Touching a high-temperature surface may cause serious burn. Please wear protective clothing and face shield before working in any area of the plasticizing system.

  

• High-temperature plastics splashing sign: High-temperature plastics and pressurized gas in the injection blend barrel may cause serious burn. Danger areas: (1) Nozzle orifice. (2) Venting port (for venting barrel). (3) Blanking port. Please wear personal protective equipment (protective clothing, face shield, safety shoes, safety gloves, and protective mask) before working on the nozzle or the plasticizing barrel.

  

• Danger: No climbing sign. Do not climb, otherwise it may damage the equipment or cause personal injuries. Danger areas: (1) Injection safety guard. (2) Injection machine body tail. (3) Clamping component guard.

  

• Danger: No treading sign. Do not tread on it, otherwise it may damage the equipment or cause personal injuries. Danger areas: (1) Cover plate of the electrical box. (2) Injection machine body, etc.

  

• Danger: Sign of no try for any person wearing a heart pacemaker. No person wearing a heart pacemaker may enter any area with electromagnetic field hazard! Danger areas: (1) Magnetic die plate.

  

• Danger: Warning sign of arc dangers. Danger areas: (1) Main power switch of the electrical box.

  

• Danger: Warning sign of collision dangers. Do not enter this area, otherwise the collision danger or moving components may cause personal injuries or pose life dangers. Danger areas: (1) Clamping component. (2) Mold installation area.

  

• Danger: Warning sign of crushing danger. Do not allow any part of your body to enter the mold closing area or come into contact with any moving component, otherwise the die plate in high-speed motion may cause personal injuries or pose life dangers. Danger areas: (1) Nozzle head. (2) Clamping mechanism. (3) Mold area.

  

• Warning: Warning sign of accumulator (optional). The machine is mounted with an accumulator. Pressure relief is required before dismounting the accumulator or its connected pipelines, otherwise high-speed jet or burst may damage the equipment or cause personal injuries.

  

• Warning: Sign of incoming line earthing. At the machine earthing site, the external earthing wire must be led to the earthing site near the sign, and the machine must be properly earthed, otherwise electric leakage or static electricity may pose the risk of electric shock or damage the machine. It is prohibited to start the machine in the absence of reliable earthing.

  

• Warning: Sign of earthing. The earthing site should be properly protected. It is prohibited to dismount the earthing wire or operate the machine in the absence of reliable earthing, otherwise electric leakage or static electricity may pose the risk of electric shock or damage the machine.

  

• Sign of careful reading of this manual. It is required to carefully read this manual before operating the machine, and prohibited to operate the machine in the absence of adequate safety devices. In the case of mold change, safety devices must be checked to see if they can normally function before operation.

  

• Sign of wearing safety gloves. The operator must wear safety gloves and other personal protective equipment before operating the machine.

  

• Sign of wearing protective mask. The operator must wear a protective mask before operating the machine.

  

• Sign of lifting position. The equipment should be lifted at the designated lifting position using qualified lifting gears by the designated lifting method, otherwise lifting may damage the equipment or cause personal injuries.

  

• Machine nameplate. Machine nameplate offers information about the company and the equipment.

  

• Electrical nameplate of the equipment. The electrical nameplate of the equipment states installed capacity and other information, and is used for electrical connection in equipment installation.

  

• Sign of the interface of mold’s ejector pin (core ejector) cylinder. A and B are the oil outlets of the solenoid directional control valve that are related to the advance and retraction actions of the ejector pin cylinder. In case of detecting opposite actions, the oil pipes on interfaces A and B can be replaced.

  

• Sign of permissible minimum mold size of the equipment

  

• Sign of maximum and minimum mold thickness of the equipment. The mold to be installed may not be used beyond this range.

  

• Indicator sign of connection of oil cooler. Please correctly connect water pipes as illustrated. The water inlet with low-temperature cooling water is at the bottom, while the water outlet with high-temperature water is at the top.

  

• Indicator sign of connection of barrel cooling water pipes. Please properly connect barrel cooling water pipes (water inlet pipe at the bottom, and water outlet pipe at the top), otherwise an excessively high temperature may cause machine faults.

  

• Indicator sign of oil level sensor (-SL). The oil level sensor automatically detects the oil level. In the case of an excessively low oil level, it sends an alarm, in which case sufficient hydraulic oil must be added to restart the equipment.

• Indicator sign of limit switch 1 for front safety gate (-SQ1). The first switch of the front safety gate is mounted in the lower left corner of the front safety gate. SQ1 is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of the front control switch of the second cut-off device (-SQ42). The second switch of the front safety gate is mounted in the lower left corner of the front safety gate. SQ42 is used for hydraulic protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of limit switch 2 for front safety gate (-SQ2). The third switch of the front safety gate is mounted in the upper right corner, and used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of limit switch 1 for rear safety gate (-SQ3). The first switch of the rear safety gate is mounted in the lower right corner of the rear safety gate. SQ3 is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of the rear control switch of the second cut-off device (-1SQ42). The second switch of the rear safety gate is mounted in the lower right corner of the rear safety gate. 1SQ42 is used for hydraulic protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of limit switch 2 for rear safety gate (-SQ5). The third switch of the rear safety gate is mounted in the upper left corner of the rear safety gate, and used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of system pressure gauge (-B1). As the pressure display device of the hydraulic system, it indicates the current actual pressure value of the hydraulic system.

• Indicator sign of stocking back pressure gauge (-B2). As the stocking back pressure display device, it indicates the current actual back pressure value upon stocking action.

• Indicator sign of machine master switch (-QF). The switch can be used to cut off utility power and control power in the machine (excluding repair lighting).

• Indicator sign of system pressure sensor (-SP6). As the pressure detection device of the hydraulic system, it automatically detects system pressure, and sends it to related equipment. In case of a fault with the sensor, it should be immediately replaced, otherwise system pressure will get out of control.

• Indicator sign of EUROMAP12 manipulator interface (-X24 EU12). EUROMAP12 interface standard is implemented here for manipulator interface type. For specific contents, please refer to the electrical schematic or relevant standard documents.

• Indicator sign of EUROMAP67 manipulator interface (-X24 EU67). EUROMAP67 interface standard is implemented here for manipulator interface type. For specific contents, please refer to the electrical schematic or relevant standard documents.

• Indicator sign of reset button (-SB1). Please confirm equipment and personal safety before resetting.

• Indicator sign of ejector advance pressure gauge (-B3). As the device displaying the actual pressure of ejection or ejector pin action, it is usually effective upon linkage action.

• Indicator sign of stocking back pressure gauge (-B4). As the device displaying the actual pressure of stocking action, it is usually effective upon linkage action.

• Indicator sign of static supporting pressure gauge (-B5). It is the device displaying the actual pressure of the moving die plate supporting cylinder.

• Indicator sign of injection accumulator pressure gauge (-B6). It is the device displaying the actual pressure of the injection accumulator.

• Indicator sign of sequence valve pressure gauge (-B7). It is the device displaying the actual pressure of sequence valve action.

• Indicator sign of control oil pressure gauge (-B8). It is the device displaying the actual pressure of the control oil of the hydraulic system.

• Indicator sign of pressure barrel pressure gauge (-B9). It is the device displaying the actual pressure in the pressure barrel.

• Indicator sign of auxiliary pressure gauge in mold adjustment (-B10). It is the device displaying the actual pressure of the auxiliary hydraulic circuit in mold adjustment action.

• Indicator sign of booster pump pressure gauge (-B11). It is the device displaying the actual pressure of the booster pump.

• Indicator sign of adding 220# extreme pressure gear oil. It is prohibited to use dirty oil, waste oil, or oil contaminated by water, steam, dirt, or sun exposure.

• Indicator sign of adding 000# lithium-based grease. It is prohibited to use dirty oil, waste oil, or oil contaminated by water, steam, dirt, or sun exposure.

• Indicator sign of adding 0# lithium-based grease. It is prohibited to use dirty oil, waste oil, or oil contaminated by water, steam, dirt, or sun exposure.

• Indicator sign of adding 46# anti-wear hydraulic oil. Hydraulic oil must be replaced after the initial 1,000 h of machine running, and then after 5,000 h of machine running or one year at most.

• Indicator sign of mounting two lubricating pumps on the machine and lubricating points. It is required to apply the required lubricant as stated on the label. It is prohibited to use lubricating oil that has been contaminated by dirt or water, oxidized, or stored for more than 18 months.

  

• Indicator sign of mounting one lubricating pump on the machine and lubricating point. It is required to apply the required lubricant as stated on the label. It is prohibited to use lubricating oil that has been contaminated by dirt or water, oxidized, or stored for more than 18 months.

  

• Indicator sign of proximity switch for end of ejector pin retraction (-SQ12). It is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of proximity switch for end of clamping (-SQ13). It is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of limit switch for end of mold adjustment advance (-SQ14). It is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of limit switch for mold adjustment retraction (-SQ15). It is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of proximity switch for electric eye in mold adjustment (-S1). It is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of limit switch for nozzle safety guard (-SQ16). It is used for electrical protection. For its control principle, please refer to the electrical schematic.

• Indicator sign of turntable clamping pressure gauge (-B12). It is the device displaying the actual pressure of turntable clamping.

• Indicator sign of turntable release pressure gauge (-B13). It is the device displaying the actual pressure of turntable release.

• Indicator sign of oiling position. Please use an oiling tool with filtering function to apply a qualified hydraulic oil. It is necessary to open the cover plate for applying hydraulic oil in some machines.

  

• Please properly mount the shockproof iron cushions before placing the machine in place! Hoist the machine to a safe height when mounting the shockproof iron cushions! Before installation, it is necessary to first screw in the nuts and remove the plain washers, then mount the iron cushions according to the diagram on the left side, and finally put back the plain washers and screw in the nuts. After all the iron cushions of the machine have been properly mounted, slowly lower the machine, and adjust the height of iron cushions via a rotary ratchet until reaching a reasonable machine level. (1) Nut (2) Small gasket (3) Screw (4) Big gasket (5) Ratchet (6) Foot pad (7) Fuselage.

  

• Please drain waste liquid (which may contain waste oil, waste water, and impurities) from the machine, and dispose of it properly. Do not directly add waste liquid into the lubricating oil tank, otherwise it may damage the equipment. Waste oil should be transferred to a professional recycling body, and should not be arbitrarily discharged.

  

• It is prohibited to open the gate while the machine is running, otherwise it may cause personal injuries.

  

• Indicator sign of incoming line wiring instructions (three-phase) (standard configuration). It is prohibited to engage in hot-line work, otherwise there may be the risk of electric shock.

  

• Indicator sign of incoming line wiring instructions (four-phase) (optional). It is prohibited to engage in hot-line work, otherwise there may be the risk of electric shock.

  

• Indicator sign of electrical box filter screen. The filter cotton must be cleaned at the interval of 2,000 h of machine running.

  

• Pressure relief valve. It is prohibited to adjust the pressure relief valve, otherwise the equipment may malfunction or be damaged!

  

• Self-sealing suction filter. The filter element must be cleaned or replaced after the initial 1,000 h of machine running, and then after 5,000 h of machine running.

  

1.5.1 Precautions

Please wear suitable personal protective equipment before operating the system and repairing the machine (such as safety shoes, safety gloves, and face shield). Please pay attention to local safety regulations on the operation safety of the injection moulding machine! Always keep the entire system in a clean state. This helps to increase the energy efficiency of the equipment and improve the safety level of the operator! Please do not remove any warning or indicator sign or label on the machine or on any additional device! Where climbing assistance is necessary for filling the material to be processed into the hopper, please use a climbing assistance device meeting national safety standards! Do not enter or touch any machine body or try to fetch a component from an opened mold during operation! Do not touch the inlet of the material to be processed! Please comply with the process specifications and safety information stipulated by the material manufacturer! Please use suction and venting devices when processing harmful materials! The motor must be kept in the off state during machine maintenance! Theoretically, the entire hydraulic system is pressureless at this point, but there may be residual pressure. Caution should be taken when operating the hydraulic accumulator! The following points should be noted when working in an area with heating fittings such as the barrel and mold:

1. 1. The nozzle must be completely disengaged from the mold! There should be no connection between the nozzle head and the mold!

2. 2. The cooling and loosening of material clogging cause high-temperature material leakage from the injection mold, resulting in combustion danger!

3. 3. Do not use the surface of the injection moulding machine as the working face!

4. 4. Do not provide any maintenance during operation!

5. 5. Detect the working safety state of all conduits. After confirming the leakage, damage, or fracture of a conduit, immediately shut off the equipment, and timely replace the conduit before restarting!

6. 6. Before repair and retrofitting, cut off the power supply of the machine, turn off the master switch, and prevent the reconnection of power supply!

7. 7. People without fixed duties are prohibited from approaching the injection moulding machine!

1.5.2 Principles and specifications to be complied with

Principles: Compliant applications of specifications. The machine is suitable only for injection moulding materials designated by the manufacturer. Processing unsuitable materials poses the risks of personal injuries and physical damage. Besides, there are also the following non-routine operations (foreseeable wrong applications), such as using the machine as a press, processing a material unavailable for plastic injection moulding, disassembling the machine, and using machine fittings. The company shall have no liability whatsoever for any loss hereby caused. Compliance with operating instructions and inspection and maintenance conditions is also within the scope of compliance. The machine is manufactured according to relevant technical standards and acknowledged safety regulations. However, the use of the machine may pose dangers to the operator or a third party, or cause machine damage or other property losses. The machine can only be operated and used by a person with adequate safety and risk awareness according to relevant regulations in the absence of technical faults! Special faults undermining safety should be cleared immediately.

1.5.3 Organization measures

Organization measures ensure proper documentation management, safety awareness, and regulatory compliance.

1.5.4 Requirements for the operator and basic responsibilities

Qualifications and certificates; basic responsibilities: The machine may only be operated by reliable, trained professionals. The operator must have received adequate training and instructions. It is also necessary to explicitly stipulate the responsibilities of the persons in charge of operation, retrofitting, maintenance, and repair! For persons currently receiving training, learning, and instructions or under conventional training, they may operate the machine/system only under the supervision of an experienced operator! The electric devices on the machine may only be operated by electrical professionals or by persons who have received instructions under the guidance and supervision of electrical professionals according to electrical technical specifications. The gas technology equipment (hydraulic accumulator) may only be operated by trained professionals. Hydraulic and pneumatic equipment may only be operated by persons with special knowledge and experience in this field!

1.5.5 Prompts about special hazards types

Described below are special hazard types that require particular attention during operation and maintenance.

1.6.1 Mechanical hazard

Wear of hoses and safety ropes: All flexible hose modules and safety ropes should be regularly checked and replaced. Cooling water hose: Cooling water hoses degrade after long-term service, so they should be replaced on an annual basis. The cooling water hose close to the barrel is exposed to high temperatures, which reduces its service life, so it should be frequently replaced. Degraded hoses become brittle, and may fracture or disengage from the joint during operation. To avoid faults, hoses should be regularly checked, and replaced when necessary. Repair of cooling water hoses should be carried out after the machine cools down.

1.6.2 High pressure leakage hazards

Hydraulic system: The flexible hose connections and pipeline systems in the hydraulic system should be correctly fastened to prevent the leakage of liquid or gas under pressure. Hoses should be regularly checked to see if there is any sign of leakage and/or blistering. A dye penetrant should be used when checking steel tubes. Skin puncture: High-pressure liquid jet may pierce human tissues, causing serious bodily injuries. In case of skin puncture by liquid jet, seek medical treatment immediately.

1.6.3 Burn risk

The injection moulding area, the auxiliary mold equipment, and the injection moulding unit’s heating components have many high-temperature surfaces. Contacting high-temperature surfaces under normal operating temperature may cause serious skin burn. These areas should all be explicitly marked with safety labels. Personal protective equipment should be worn before working in these areas. High-temperature surface Caution: The heating temperature of some materials may exceed 240°C, causing the surface temperature of the barrel safety guard to exceed the limit value. Thus, to avoid burn risk, it is prohibited to touch the surface of the barrel safety guard during operation. Fused materials: Fused materials may have a seemingly cool surface, but their internal temperature is still very high. Personal protective equipment should be worn before disposing of materials cleared out. It is prohibited to touch the processed materials cleared out or flowing out of the nozzle or the mold, or the materials in the charging opening area.

1.6.4 Explosion spray hazard

The raw material is degraded: The pressure built up around the nozzle orifice or in the charging opening area may cause some processed materials to explode. In some circumstances, fused materials may accidentally eject due to the inadequate drying before processing or the degradation of processed materials. These areas should all be explicitly marked with safety labels. Pay special attention to these areas. Make sure to wear suitable personal protective equipment (such as face shield, protective clothing, safety gloves, and safety shoes). Note in particular that plastic raw materials may reside beyond the safe period in the high-temperature barrel, and cause explosion as a result of continuous high temperature. The user is duty-bound to control and avoid such circumstances. Residual high pressure: Injection action unexpectedly interrupted, nozzle, mold cavity, mold flow to the inside, there may be residual high pressure, there is the risk of accidental injection. You must first do the shooting back action, so that the residual high pressure relief, and then do the seat retreat action, so that the nozzle and mold separate, before allowing the operation of the machine.

1.6.5 Electrical hazards

Electrical hazards: Moulding equipment uses high-ampere current under high voltage. Power requirements are marked on the electrical control cabinet’s electrical nameplate and electric circuit diagram. It is required to connect the equipment to a suitable power source as shown in the electric circuit diagram, and comply with all applicable local regulations.

1.6.6 Arc flash hazards

Arc flash hazards: The main power switch of the moulding equipment poses the potential safety hazard of arc damage when it is turned on/off.

1.6.7 Magnetic field hazard

Magnetic field hazard: Magnetic fields may cause harm to pregnant women or persons who have received a medical implant. They usually emerge on the following occasions:

Persons wearing an active implant (such as a heart pacemaker) must keep a distance of at least 100 cm away from hazards areas. Pregnant women must keep a distance of at least 50 cm. Opening the safety gate increases risks. Thus, the operator of the system is duty-bound to assess the harms which may be caused by the workplace to related personnel, and take suitable measures in case of any harm. Magnetic die plate system: Heart pacemakers, hearing aids, and other medical devices may be affected or damaged by the magnetic field of the magnetic force holding system. It is not allowed to use any ferrous article or tool after the magnetic die plate is magnetized. A strong magnetic attraction force may cause personal injuries. It is not allowed to magnetize the magnetic die plate before the mold comes into full contact with the magnetic surface of the magnetic die plate. Please carefully read the manual of the magnetic die plate, and strictly comply with relevant provisions.

• (1) Supply cables

• (2) Main power connections

• (3) Transformer and driver shell

• (4) Motor (servo motor)

• (5) Magnetic die plate mounted on the machine

• (6) Permanent magnets (such as the fixators of sliding gates)

1.6.8 Noise hazard

Noise hazard: Under normal operating conditions, the noises emitted by one injection moulding machine would not cause harms. However, long-term exposure to excessive noises may cause damage to hearing. Make sure that the noise level conforms to all applicable local regulations. Wear ear protection before operating the equipment. Caution: Wear ear protection when the noise value exceeds 70dB(A). For the noise values of this series of injection moulding machines, please refer to the table 1.6.8.1.

1.6.9 Gas/steam/dust emission hazards

The inherent design of this machine makes it unsuitable for processing materials which may emit harmful gas, smoke, or dust. To process a material which may emit harmful gas, smoke, or dust, the user should mount a venting system. Please contact our company for the specific installation method of venting systems. Where a user arbitrarily alters the inherent safety structure of the machine to install a venting system without the permission of the company, the company shall have no liability whatsoever for any consequence hereby caused. Some processed materials may emit harmful gas, steam, or dirt. Venting systems should be mounted according to local regulations. A venting system can be mounted in the mold area of the injection moulding machine or in the upper space of the nozzle activity area, and the venting interface can be mounted in suspension type. See details in Figure 1.6.9.1. Warning: When nitrogen is used during production, oxygen content must be constantly checked before working on site.

1.6.10 Slipping/tripping/falling hazards

Warning: It is prohibited to walk, stand, climb, or sit on machine surface. No position without a sign of access on the machine may be used for access, otherwise it may cause slipping/tripping/falling hazards. A qualified platform or ladder around the equipment should be used to access areas which would be otherwise inaccessible from the ground.

1.6.11 Hoisting hazards

Caution: Suitable hoisting equipment, correct balancing technology, and designated hoisting points should be used for hoisting the machine or its components. For instructions about handling and hoisting, please refer to detailed installation steps. It is prohibited to exceed the rated hoisting capacity of the hoisting equipment.

1.9.1 Protective cover or protective door

Figure 1.9.1.1 Schematic diagram of guards of the machine.

Protection function of the protective cover (or protective door): To prevent any person or object from entering the dangerous area. To prevent the melted plastic from splashing out to hurt people. When the movable protective door is opened, the safety mechanism will discontinue any dangerous mechanical motion. Movable protective door in the die area: Both sides of the area where the die is installed each have one movable door, above which there is one movable top cover plate (no top cover plate for medium and large-sized machines). The movable door and top cover plate must be closed after the die is installed. Caution: Do not conduct operations with the top cover plate removed. If the machine needs to be equipped with a manipulator, it is allowed to remove the top cover under the premise of ensuring safety. Nozzle guard: To prevent the high-temperature melted plastic from being ejected to hurt people, install a nozzle protective cover at the operation position of the nozzle (see Figure 1.9.1.2). Warning: Operations with the protective cover removed are not allowed.

• (1) Upper fixed protective cover (medium and large machines are not installed).

• (2) Mobile protective net (emergency door), one on each side.

• (3) Moving top cover plate (medium and large machines are not installed).

• (4) Nozzle guard.

• (5) Injection protective cover.

• (6) Secure the protective cover.

1.9.2 Mechanical safety mechanism

Mechanical safety device: Mechanical safety device is an important device to ensure personal safety and mold safety, whose working principle is: when the front safety gate is opened, the safety brake shoe will fall down to prevent the passage of battering ram, so as to prevent mold closing. Therefore, you should always check its reliability. Do not remove it without authorization. See Figure 1.9.2.1.

Caution: Check and adjust the safety brake shoe regularly. Ensure that the brake shoe can freely fall down when the safety gate is opened. After adjusted, it should be repeatedly tested to ensure good protection function. After the safety gate is completely closed, ensure that there is a 3~5mm gap between the battering ram bottom and the brake shoe, thus preventing the line from being under tension.

• (1) The safety gate pulls the line.

• (2) Rotor plate.

• (3) Impact plate.

• (4) Safety switch pressure block.

• (5) Safety striker.

1.9.3 Electrical safety device

Safety devices of electrical appliances include basic molded case circuit breaker, miniature breaker, grounding wire, E-stop button, and limit switches of all protective doors (covers).

1.9.4 Hydraulic safety device

Hydraulic safety system includes:

Caution: Do not adjust the system safety valve under any circumstances.

• (1) Hydraulic protective valve of the safety gate. When the front movable safety gate is opened, the oil line of mold closing will be cut off by the safety valve, and then mold closing stops.

• (2) System safety valve. The manufacturer has set up the maximum allowable value and closed it. It limits the maximum pressure of the system. If the pressure value exceeds the specified value, the system safety valve will be started. The safety valve limits the pressure of the hydraulic system and protects the operator and hydraulic components, such as oil pump and pipe fittings.

1.9.5 Auxiliary equipment

If the user of this machine needs to equip auxiliary equipment, only when such equipment is installed according to EN ISO 20430 can this machine be operated. The Company is only responsible for the interface interaction of the self-designed injection machine and auxiliary equipment. If the user removes the auxiliary equipment, the EN ISO 20430-compliant guard or safety device should be reinstalled.

1.9.6 Loading platform and auxiliary device

Loading platform: The Company strongly recommends that the user should load materials with an automatic loading system. If manual loading is adopted, its loading platform must conform to relevant national standards. The Company may as well provide the user with technical support for the loading platform, as shown in Figure 1.9.6.1 Schematic diagram of elevated loading. Warning: Attention! Extrusion risk of moving parts. The unauthorized auxiliary engine that is not permanently installed will bring the operator into the dangerous area of the machine. The auxiliary device and auxiliary engine to be equipped for the machine must conform to relevant national standards. Before production, the auxiliary ladder should be in place. As the auxiliary ladder is at the risk of contamination by oils and plastic particles, they should always be kept clean. If contaminated, they should not be used. The operator should not contact the dangerous area of the machine through the auxiliary ladder.

2.3.0.1 Cooling water quality requirements

Cooling water quality: To ensure the failure-free operation of cooling system, the cooling water must conform to the following moisture requirements. Carry out hydrolysis when necessary. Caution: Danger! Damage caused by cooling system. The cooling water that fails to satisfy quality requirements will result in fault and damage, such as pitting spots and water scale. Please confirm that there are not any materials that might damage the cooling system in the cooling water and other media in contact with the cooling system. Decalcification: Recheck the flow and return water temperature on a regular basis. In case of drastic change, it generally indicates the reduced cross section in the cooling cycle. Please decalcify the cooling system regularly with a set of commercial standard decalcification system. Cooling water additive: Cooling water additives (such as anti-freezing agent and algaecide or calcium remover) should not contain materials likely to react with the cooling system. Please pay attention to the manufacturer's data sheet. Please pay special attention to

2.3.0.2 Permissible water parameters

the materials that react with cooling water additive, including EPDM, FKM, NBR, PA, PC, POM, PTFE, TPE, TPU, copper, and aluminum. Cooling water pressure: The intake pressure of cooling water for the machine should be between 3bar and 6bar, not more than 8Bar. The intake temperature of cooling water should be lower than 20°C. Cooling water flow: See the table 2.3.1 below for the cooling water flow required by various machine types. Table 2.3.1 Cooling water flow. Precautions: Cooling system washing. Warning: Contamination hazards of drinking water network. Do not directly connect the machine's cooling system to the drinking water network. In the closed system, please mainly use industrial water in the cooling system. To save water, it is recommended to recycle the cooling water. Caution: Environmental pollution. The hydraulic oil of the machine can contaminate the soil and water. Do not dump the sewage mixture produced in the flushing process into the sewer. Pay attention to national and local laws and regulations in connection with the removal of dangerous fuels.

2.5.1 Hydraulic Oil Type Codes

Specifications and naming conventions for hydraulic oils.

2.5.2 Cleanliness Class and ISO 4406 Standards

Cleanliness standards for hydraulic oil following ISO 4406 are critical for system reliability.

2.5.2.1 Contamination and cleanliness requirements

Cleanliness class of hydraulic oil: According to the findings of relevant research institutions, about 80% of hydraulic system failures are caused by contaminated hydraulic fluid. Therefore, in addition to the basic properties, such as viscosity, temperature stability, and anti-wear protection, the cleanliness of hydraulic fluid plays a decisive role in the failure-free operation of the injection machine. Generally, contamination involves hard particles, such as dust and wear residues or soft particles produced by the aging process. Soft particles may accumulate on hydraulic parts or filter in sticky form and limit the function of components. To determine the degree of contamination, the so-called "cleanliness class" has been divided. The number and size of particles per 100 ml of hydraulic oil will be determined. The methods used to determine the oil cleanliness and classify the cleanliness class are defined in ISO 4406:1999. ISO 4406:1999 (International Standardization Organization) The particle size is classified as per >4 µm, >6 µm, and >14 µm. The number of particles obtained by counting will be determined cumulatively and explai

2.5.2.2 ISO 4406 classification and maintenance

ned according to the ordinal number specified in the ISO 4406:1999 standard. Applicable determination method: The higher the ordinal number, the more the number of particles, the higher the degree of contamination. For instance, cleanliness class 18/15/12 represents: 18 indicates particles whose size is >4 µm. 15 indicates particles whose size is >6 µm. 12 indicates particles whose size is >14 µm. According to the components used in the hydraulic circuit of the injection machine, such as pump and valve, the following values of cleanliness class are the highest allowable thresholds.

2.5.2.3 Maintenance and monitoring

Table 2.5.1 Maximum permitted threshold. When other filtering methods are used to continuously improve the service life, the cleanliness class as specified in ISO 4406:1999 - 15/12/09 must be maintained (see the first paragraph in liquid management). Caution: It is required to check (analyze) the hydraulic oil of the injection machine once a year. All additional filtering methods cannot replace the oil replacement specified by the maintenance plan. In case of severely aged hydraulic oil, acidic oil components may corrode hoses and sealing gaskets (washers).

2.5.3 Liquid Management and Condition Monitoring

Liquid management and condition monitoring for hydraulic systems.

2.5.4 Lubricating Oil and Grease Specifications

Lubricating oil and grease specifications for the injection moulding machine.

2.5.4.1 Factory greases and requirements

Initially filled lubricating grease and lubricating oil: For this, the oil analysis by the professional testing institution must be observed. See the machine maintenance section for the time interval specified in the maintenance plan. Table of lubricating oil (grease): Select the following hydraulic oil and lubricating oil (grease) of proper types according to the instructions of hydraulic oil manufacturer/hydraulic device component supplier. Caution: Use optional lubricating oil (grease). High-quality lubricating oil (grease) used during initial filling can ensure a longer service life of the machine.

2.5.4.2 Recommended grease tables

Only when these lubricating oils (greases) are strictly used can the lowest possible wear be ensured. As optional lubricating oil (grease), only the permitted lubricating oil (grease) listed in this chapter is allowed to be applied at the corresponding lubricating points. Hydraulic oil 46 or 68: The quality of hydraulic oil must reach NAS1638 (American National Standard) class 7 to 9; The table below shows the permitted hydraulic oil. Table 2.5.2 Hydraulic oil 46 or 68. Lubricating oil: The table below indicates the permitted brands and specifications of lubricating oil. Table 2.5.3 Lubricating oil.

3.1.1 Warnings and safety requirements

Warning: Risk of heavy falling objects. There always are dangers caused by heavy falling objects during the transportation. Never stand under the lifted heavy object or step into the area under heavy objects. Compare the piece weight of the machine with the bearing capacities of rope and crane as well as auxiliary traction equipment before transportation. Select means of transport with sufficient safety and load. Properly lock the rope on the crane hook during the transportation with the crane, to prevent the overturn of heavy objects, as their center of gravity might be eccentric. For the transportation by forklift, note that the forklift should have sufficient bearing capacity and fork size. Please refer to the manual for details of related machine size and weight. Risk of slip. During transportation, working materials (such as hydraulic oil) may flow out and pollute the environment around the machine.

3.1.2 Transport procedures and precautions

Drain the machine and/or prevent the leakage of working material containers before transportation. In case of overflowing working materials, they must be removed immediately according to the environmental requirements. Wear personal protective equipment. Danger of personal injury may occur during transportation. Always wear personal protective equipment (such as safety shoes and protective gloves) based on the currently valid accident prevention regulations during transportation. During air transportation and sea transportation, the pressure of nitrogen in the energy accumulator (for all machines equipped with energy accumulator) should be reduced to about 10bar. Climbing aids and working platforms that meet safety rules must be used for installation and disassembly at the height above the head. Do not use machine components as the climbing aids.

3.3.1 General lifting requirements

Lifting: The movable platens of all machines should have the minimum mold thickness before lifting. The crane or other hoisting equipment, hook, sling, or steel wire rope compatible with the machine weight. See the list of technical parameters for the machine weight. A number of wood blocks and waste cloth. Well-maintained foundation; or solid and flat concrete ground. Warning: Do not hang the lifting rope on the parts of the machine with weak bearing capacity. Operations must be carried out strictly based on the Schematic diagram for lifting. The lifting and installation work must be conducted by professional lifting workers with abundant lifting experience. Pay attention to the machine stability during the lifting. Always keep it horizontal in the process of lifting and handling. Do not stand under the machine during lifting.

3.3.2 Lifting procedures by machine size

Illustration of lifting of small-scale machine: Figure 3.3.1 Schematic diagram for lifting of small-scale machine. Lifting of clamping mechanism of medium-scale machine: It is recommended to use lifting-specific flexible rope or sling. If the steel wire rope is used, wood block or waste cloth must be placed beneath. Figure 3.3.2 Schematic diagram for clamping mechanism lifting of medium-scale machine. Caution: There are lifting rings on the rear platen of split-type body. Lifting of injection components of medium-scale machine: If the steel wire rope is used, wood block or waste cloth should be placed at the position of the machine where the rope is hung. It is recommended to use lifting-specific flexible rope. Figure 3.3.3 Schematic diagram of lifting of injection components of medium-scale machine. Lifting of large-scale machine: It is recommended to use lifting-specific flexible rope or sling. If the steel wire rope is used, wood block or waste cloth must be placed beneath. Figure 3.3.4 Schematic diagram for lifting of clamping components of large-scale machine. Caution: To facilitate packaging and transportation, a machine with a clamping force of over 2,000t will be split into more assemblies or parts for respective lifting due to its large volume and weight.

4.4.1 Inspection of nozzle center

Inspection of nozzle center: The nozzle center is the axial position of the nozzle relative to the center hole of fixed pressure plate. Check and adjust the nozzle center in the following situations:

The body direction has great impact on the nozzle center. Therefore, first check the alignment of the body before checking the nozzle center. See the table 4.4.1.1 of nozzle center. Table 4.4.1.1 Tolerance of nozzle center. (1) Before the installation of injection mold. (2) The nozzle head is flush with the installation surface of fixed form mold. (3) The barrel is heated. (4) The machine motor is closed. Warning: Risk of sputtering. Red-hot plastic raw materials are likely to be ejected from the nozzle hole. Be sure to completely discharge the plastic raw materials in the barrel before measurement. High temperature. The red-hot parts of the machine will result in a risk of burns. Please wear protective clothing and mask. Measurement Method: Measure vertical and horizontal distances between the nozzle and the center holes on both sides. See Figure 4.4.1.1 below for details: Figure 4.4.1.1 Schematic diagram for measurement method of nozzle center. Information: Settings of nozzle center. If the center of the nozzle is out of tolerance in vertical or horizontal direction, such center must be adjusted.

• (1) After machine transportation.

• (2) If the machine has been adjusted.

• (3) After the repair and maintenance of injection assemblies.

4.4.2 Adjustment of nozzle center

Adjustment method of nozzle center:

Figure 4.4.2.1 Schematic diagram for the injection bracket (1) Fastening screws connecting the front and rear brackets to the fuselage. (2) Upper and lower trim bolts. (3) Lock nut of left and right adjusting bolt. (4) Left and right adjusting bolts. (5) Rivet connection. (6) Front and rear brackets. Figure 4.4.2.2 Schematic diagram for the measurement position of nozzle center.

1. 1. Prepare a vernier caliper.

2. 2. Ensure that the levelness of the machine has been properly adjusted before the adjustment of nozzle centrality.

3. 3. Loosen the fastening screws connecting the front and rear brackets of the guide rod of injection seat to the body, as shown in Figure 4.4.2.1.

4. 4. Loosen left and right adjusting bolts.

5. 5. Measure L1, L2, L3, and L4, adjust left and right adjusting bolts to make L1=L3, and adjust upper and lower adjusting bolts on front and rear brackets to ensure L2=L4, as shown in Figure 4.4.2.2. Refer to the table of nozzle center tolerance for the centrality error range.

6. 6. Tighten all fastening screws and lock nuts after the adjustment.

4.4.3 Selection of nozzle

Conditions for the selection of nozzle: Nozzles are selected based on the specifications of the mold. We provide a lengthened nozzle as an accompanying accessory. If necessary, it can also be customized according to the special requirements of the client. For the selection of spherical radius (R) of the mold gate, it must be larger than the spherical radius (r) of nozzle, as shown by A in Figure 4.4.3.1 below; otherwise, it will lead to poor contact between nozzle and mold, with the risk of spillage and the possibility of short moulding, as shown by B in Figure 4.4.3.1 below. Figure 4.4.3.1 Schematic diagram for fitting between nozzle and mold (1) Mould (2) Nozzle.

6.7.2 Preparations before mold installation

Preparatory work:

Table 6.7.2.1 Data of different models. Caution: Mold installation size should not exceed tie bar clearance. The mold integrator is duty-bound to make sure the mold in ejection or ejector pin action would not come to a dangerous stop.

1. 1. Necessary tools: vernier caliper, tape, level instrument, Allen wrench, bayonet wrench, socket wrench, multimeter, driver, paper cutter, copper rod, and radius gauge.

2. 2. Measure mold length, width, and height with a tape. Judge whether the mold can be installed on the machine by referring to the tie bar clearance and maximum/minimum mold thickness in the technical parameter table in Volume 2 of this manual and the data in the following table.

3. 3. Measure the outer diameter of the locating ring of the mold using a vernier caliper with reference to the mold installation diagram in the Volume 2 of this manual, and judge whether it fits well with the mounting hole on the fixed die plate.

4. 4. Use a radius gauge to measure the spherical radius of the mold gate, and a vernier caliper to measure its inner hole diameter and depth. Judge whether the injection blend nozzle of the machine fits well with the mold.

5. 5. Measure the ejector plate and ejector hole sizes of the mold with a vernier caliper and a taper, and judge whether they fit well with the machine.

6.7.3 Steps of mold installation

Prepare clamping cap, pressure plate padding block, holding-down bolt, nut, plain washer, spring washer, wrench, and cooling water pipe. Also prepare air pipe (blowing function), oil pipe, and joint (ejector pin function).

Caution: For bolt size, please refer to the mold installation chart in Chapter 9. Control the screw-in depth of bolts at 1.5~1.8 times of bolt diameter. Tighten bolts firmly to prevent mold falling during mold opening. Observe the length of the nozzle and the depth and size of the mold feed inlet before nozzle movement to see if there are interferences, as they may damage the nozzle or heater bands.

1. 1. Turn on power supply, and set mold opening clearance according to the spatial distance required for mold release after mold opening. Set ejection stroke according to the design parameters of the mold and the distance required by the product, and select necessary ejection function.

2. 2. Start the pump motor, and press the mold adjustment key to enter mold adjustment state. Manually adjust mold thickness to the required value in mold adjustment mode according to the actual thickness.

3. 3. Perform mold opening to open the die plate to the set position; Conduct ejection advance, adjust the number of ejector pins, and remove excess ejector rods to fit with the mold.

4. 4. Move the injection blend backwards; Turn off the oil pump motor.

5. 5. Hoist the entire mold (make sure that the mold core and cavity cannot be disengaged during hoisting), and place it into the die plate (take caution to prevent the mold from coming into contact with the tie bar or other machine components).

6. 6. Mount the locating ring into the mounting hole of the fixed die plate, so that the mold plane fits with the mounting face of the fixed die plate.

7. 7. Use bolt, clamping cap, pressure plate padding block, plain washer, and spring washer to partially fix the fixed die plate using a moderate clamping force.

8. 8. Start the oil pump motor. Press the mold adjustment key to enter mold adjustment state.

9. 9. Perform mold closing in jog mode, so that the moving die plate gradually comes into contact with the mold until clinging to it. Turn off the oil pump motor.

10. 10. Tighten clamping cap bolts on the fixed die plate and the moving die plate, and clamp the entire mold. Take off the slings used for hoisting.

11. 11. Properly set various positions, pressures, and speeds of mold opening/closing, and, in particular, set high-pressure clamping pressure to the pressure required by the molded product.

12. 12. Start the oil pump motor. Start with mold opening, and end with mold opening. Close the safety gate, and press the secondary mold adjustment function key to enter automatic mold adjustment state. Switch on and off the safety gate again for automatic mold adjustment, after which the machine is restored to manual mode.

13. 13. Press the mold closing key for mold closing, and turn off the oil pump motor after mold closing.

14. 14. Tighten all the fastening bolts of the mold again.

15. 15. Connect other mold-related pipelines, such as cooling water pipe, core-pulling oil pipe, and manifold control cable. End mold installation at this point.

6.8.1 Precautions for injection moulding work

Observe the following safety precautions before and during injection moulding work.

6.8.2 Hydraulic oil temperature

The optimal working temperature of hydraulic oil is 40°C - 46°C, as a temperature below 40°C means excessively high viscosity and a temperature above 55°C means excessively low viscosity. Injection moulding will be affected when hydraulic oil temperature is too high or too low. To achieve the optimal state for the machine at the beginning of injection moulding (such as oil temperature below 40°C), hydraulic oil should be preheated first. Preheating work can be performed either by only starting the oil pump motor for idling, or by conducting a certain action (such as ejector pin advance or ejector pin retraction) and setting certain pressure and flow, so that oil temperature rises up faster.

6.8.3 Steps of injection moulding work

1. 1. Set barrel heating temperature according to the plastics and product currently used, and start follow-up work about 15 min after plastic temperature reaches the set temperature.

2. 2. Open the hopper cap, pour in plastic raw materials, and cover it up (where there are feeder and drying hopper, please follow their operating instructions).

3. 3. Roughly set the ending position, pressure, and speed of stocking and properly adjust the pressure of the stocking back pressure valve according to the weight of the product, the weight of raw materials, and the total injection volume of the machine. Set parameters related to injection and holding. Note that there are two methods of adjusting stocking back pressure, i.e., manual adjustment and panel setting (proportional back pressure). Indicate such information upon selection. Note that various pressure values are displayed on pressure gauges, and that each gauge has a noticeable rating plate. Notice: Big back pressure will add the consumption energy.

4. 4. Press the motor starting key to start the motor.

5. 5. Press the mold closing key for mold closing action until the end of moulding closing.

6. 6. Press the injection blend advance key to advance it until the nozzle and the mold gate fit with each other. Notice: step 5 and 6 maybe different according to different material and mold.

7. 7. Press and release the stocking button, so screws rotate and gradually retract to the set position, and then stop stocking. Note that the stocking button can also be pressed during stocking to stop stocking action.

8. 8. Press the injection key to start injection action and holding action.

9. 9. Loosen the injection key at the end of holding, and press the stocking key to start the stocking of the next mold.

10. 10. At the end of stocking, press the mold opening key after a roughly sufficient cooling time to perform mold opening action.

11. 11. At the end of mold opening, perform ejection action to open the safety gate and take out the product.

12. 12. Observe the moulding status of the product, and adjust relevant parameters accordingly.

13. 13. Repeat the above steps and adjust parameters constantly until a qualified product is molded.

14. 14. After a qualified product is obtained, press the semi-automatic or full-automatic key to enter automatic working state.

6.8.4 Steps of ending injection moulding work

1. 1. End injection moulding work first when plastics raw materials have been used up, the products required have been finished, or the machine needs to be turned off.

2. 2. Press the manual button after injection, and close the hopper inlet.

3. 3. Turn off the dryer and cut off power supply to the feeder.

4. 4. Thoroughly drain excess stock from the heated barrel (press the automatic purging key), and prevent melted resin from being retained in the barrel, so that the barrel can be heated within the shortest time possible in the next injection moulding operation.

5. 5. Turn off barrel electric heating. Please do not turn off barrel electric heating in the case of temporary shutdown.

6. 6. Perform mold closing in mold adjustment state, so that the two halves of the mold completely fit with each other. Do not enter high-pressure clamping. Retract the injection blend and screws to stop position. Turn off the oil pump motor, and cut off the main power of the injection moulding machine. In the case of a lengthy shutdown, spray an anti-rust agent on the core cavity of the mold.

7. 7. Cut off the cooling water source of the mold (for instance, in the case of a lengthy shutdown, completely drain cooling water from the cooling systems of the mold and the machine).

8. 8. Cut off the air and power supply of the machine.

7.4.1 Safety precautions for lubrication and maintenance

Caution: Wear goggles before performing lubrication or any hydraulic oil-related operation. Take special caution, as splashing hydraulic oil or lubricating grease may seriously injure your eyes or impair your vision. It is prohibited to use lubricating oil contaminated by water, steam, dirt, or sun exposure. Collect and clear waste lubricating oil/lubricant according to environmental protection requirements, and transfer them to a qualified recycling body for proper disposal.

7.4.2 Composition and characteristics of lubricating system

Composition of lubricating system: The lubricating system is composed of lubricating oil pump, lubricating oil circuit, lubricating oil distributor, lubricating points, and system-end pressure sensor. Lubricating oil is first delivered to various lubricating oil distributors, which then distribute it to various lubricating points to lubricate various moving components of the injection moulding machine. Control of lubricating system: The lubricating system is controlled by a machine controller, which monitors the service state of pressure sensors, the oil levels of lubricating pumps, and the lubrication status of the lubricating system. The controller sends an alarm during lubrication in the following circumstances: oil shortage in the oil tank, oil leakage from system pipelines, clogging of oil pump filter screens, and low oil pressure. Upon receiving the alarm, it is necessary to check the reasons of poor lubrication, and timely fill lubricating oil when necessary.

7.5.1 Lubrication mechanism of fixed-resistance lubricating system

Mechanism of fixed-resistance lubricating system: The injection moulding machine adopting fixed-resistance lubrication is configured with damping distributors. When the lubricating oil pump is in service, due to the role of the damper, lubricating oil with a certain pressure is accumulated in the oil circuit from the oil pump outlet to various distributors. When the pressure of lubricating oil is higher than damping pressure difference, lubricating oil will overcome damping, and continuously flow towards various lubricating points until lubrication is over. Adopting damping holes variable in size, damping distributors ensure that oil is allocated by the lubricating system to various lubricating points as needed. Where the pressure of the lubricating oil circuit fails to reach the pressure value set by the pressure relay within lubrication time (i.e., lubrication alarm time), the machine will send an alarm reporting the problem with the lubricating system.

7.5.2 Lubrication mechanism of quantitative pressurized lubricating system

Mechanism of quantitative pressurized lubricating system: The injection moulding machine adopting quantitative pressurized lubrication is configured with quantitative pressurized distributors. When the lubricating oil pump is in service, it pressurizes various distributors, and pushes the lubricating oil in the upper cavities of quantitative distributors towards each lubricating point, thus evenly lubricating each lubricating point. When the pressure of the lubricating oil circuit reaches the pressure setting of the pressure relay, the oil pump stops, and the computer starts lubrication delay timing. Each distributor is depressurized, and automatically replenishes lubricating oil from the oil circuit to the upper cavity. At the end of lubrication delay timing, the oil pump restarts, and repeats the above steps until the total lubrication time is over. Adopting variable displacements, quantitative distributors ensure that oil is allocated by the lubricating system to various lubricating points as needed. Where the pressure of the lubricating oil circuit fails to reach the pressure value set by the pressure relay within lubrication time (i.e., lubrication alarm time), the machine will send an alarm reporting the problem with the lubricating system.

7.7.1 Structure of cooler

Structure of water-cooling cooler: The water-cooling cooler is composed of inlet cover, tube plate, pipe barrel, heat transfer tube, baffle plate, sealing washers, and struts, as illustrated below. The space enclosed by the heat transfer tube’s outer surface, the pipe barrel, and other links is called the shell side. The interior of the heat transfer tube and the space connected with it is called the tube side. Heat is exchanged between shell-side fluid and tube-side fluid via the heat transfer tube to lower the temperature of high-temperature fluid and achieve cooling purpose. Figure 7.7.1.1 Structure of cooler (large-sized machine, installed externally) (1) Water inlet cover (5) Tube (2) Baffle (6) Install the tripod (3) Heat transfer tube (4) Return cover. Figure 7.7.1.2 Structure of cooler (small-sized machine, installed internally) (1) Water inlet cover (2) Baffle (3) Heat transfer tube (4) Mounting flange (5) Tube.

7.7.2 Model and use of cooler

Caution: Coolers may not be used beyond the pressure or temperature range indicated on the product nameplate and Product Certificate. Coolers may only use fresh water as the cooling medium, unless in the case of special orders. Coolers must be regularly cleaned, and completely drained when they are not to be used for a long time; In the cold winter, cooling water must be timely drained out once a cooler stops, so as to prevent frozen cooling water from damaging the cooler. Used fresh water may not be directly discharged into the drinking water pipeline network or nature, and should be transferred to a qualified wastewater treatment agency for proper disposal. Water quality requirements: For fresh water quality requirements, please refer to the following table: Table 7.7.2.1 Fresh water quality requirements. Cooler data: Cooler model and cooler inlet/outlet thread size, as provided in the table below. Table 7.7.2.1 Cooler model and cooler inlet thread size.

7.7.3 Detection, maintenance, and cleaning of cooler

Detection of cooler: Refer to the structure of the cooler, and open its end cover for check:

Better dismount the cooler from the machine for the convenience of detection. Constantly check equipment status, and determine the detection cycle of the cooler according to actual circumstances. Check municipal water supply about every half a year (six months). Check industrial water and groundwater about once every month, as they contain lots of salts. The maintenance of the heat exchanger: If the machine is not in use at a longer time, please let fluid out from the heat exchanger; In severe cold weather, after the heat exchanger cooler stops working, the cooling water in the heat exchanger should be emptied in time to avoid damage caused by cooling water freezing. Common failure and the treatment of the failure: Table 7.7.3.2.1 Common faults and their handling methods. Cleaning of the heat exchange: If the cooling effect falls down, then the heat exchange may need cleaning. Covered at both ends removed to check whether there is anything of dirt or corrosion. At least every six months to clear the heat exchange. The use of commercially available alkaline cleaning liquid, cleaning the main house and the heat transfer tube. Interlayer for the intractable, to be used in weak hydrochloric acid cleaning, washing the main and heat transfer control by running water. More heat transfer tubes when the inner scale, use of cleaning agents dissolved immersion scale, and then with water and suitable for washing brushes. Caution: Clear up residual cleaner from the cooler. Flush away residual chemicals with water before reassembling the cooler, and dry it with compressed air. Cleaning sewage may not be directly discharged into the drinking water pipeline network or nature, and should be collected and transferred to a qualified wastewater treatment agency for proper disposal.

• 1. Check the surfaces contacting with the cooling medium and the inner wall of the heat transfer tube to see if there is incrustation, dirt, or corrosion.

• 2. Check all sealing washers to see if they are intact.

• 3. Check the outer surface of the heat transfer tube, the inner surface of the pipe barrel, and other surfaces contacting with oil, and see if there is dirt, impurity, or corrosion.

7.8.1 Filter

The filter is essential for the normal service of the hydraulic system, and should be regularly checked. Relevant circumstances should be taken into account in deciding whether to clean or replace the filter element, or even replace hydraulic oil. On some machines the filter is installed with an alarm device, which utilizes the pressure difference produced by the hydraulic oil flowing through the filter. Where an excess pressure difference causes the point of the pressure gauge on the filter to point towards the red zone or the machine gives a filter alarm, it means that the filter is too dirty and needs to be cleaned or replaced. Suction filter: The suction filter is mounted at the oil pump inlet on the oil tank side, and used to filter hydraulic oil. Two types of suction filters are often used on the machines of our company. Self-sealing suction filter: The first type is self-sealing suction filter (see Figure 7.8.1.1). To replace/clean the filter element or repair the system, it is necessary to first unscrew counterclockwise the big screw in the middle of the filter end cover (in which case the self-sealing valve automatically closes to insulate the oil tank circuit and prevent oil from flowing out of the oil tank), then loosen the six screws around the end cover and dismount the end cover, and finally pull out the filter element for replacement or cleaning. Plain suction filter: The other type is plain suction filter (see Figure 7.8.1.2), which is directly mounted on the suction pipe of the oil tank. The oil filter can be directly taken off from the suction port for cleaning. Bypass filter: Some machines is also mounted with a bypass filter. After unscrewing the T pattern on the end cover, the filter element can be pulled out for cleaning or replacement, as shown in Figure 7.8.1.3.

7.8.2 Magnetic bar of the oil tank

Magnetic bar of the oil tank: The magnetic bar of the oil tank is fixed on the tank cover, and used to adsorb the metal powder brought by hydraulic oil into the oil tank. It needs to be cleaned, as shown in Figure 7.8.2.1.

7.8.3 Cleaning

Cleaning method: Use light oil, gasoline, or flushing oil to thoroughly remove all foreign matters clogging the wrapping wire, and remove all the metals on the middle magnetic bar. Introduce compressed air from inside, push it outwards from the filter element, and blow foreign matters away from the wrapping wire.

7.8.4 Precautions

Caution: Do not start the oil pump of the machine after the oil filter is dismantled (removed). Do not fix the nozzle of the air blowing pump too tightly when compressed air blowing is adopted. Where the wrapping wire of the filter element has been damaged and cannot be used any more, use a new filter element. Take caution not to damage the wrapping wire when dismounting and mounting the filter. Check the filter end cover to see if it has been tightened after mounting the filter element and before starting the oil pump. Allow the oil pump to run without load for 10 min after filter installation, and start loaded running only when there is nothing abnormal.

7.12.1 Dismounting, mounting, and cleaning of the nozzle

The barrel module related to the thermoplastics process is described below. Where the resin produced by the machine is PC, PVC, PA, or ABS, dismounting is allowed only after the machine has been cleaned using PS, PE, PP, or other special-purpose cleaners. Dismounting of nozzle:

Figure 7.12.1.1 Nozzle dismounting diagram. Cleaning and mounting: 1. Please thoroughly clean the nozzle, and apply high-temperature lubricating grease on the thread and the face fitting with the front barrel. Applicable heat-resistant lubricating grease (such as MoS2). 2. Screw in the nozzle again (right-hand thread). Untightened. 3. Heat the nozzle for about 10 min, and tighten it according to the thread diameter and tightening torques of screws (or bolts) described in 7.3. 4. Reinstall the nozzle band heater (evenly tighten fixing screws). 5. Tighten the thermocouple (check whether the fixing hole is clean). Figure 7.11.1.2 Nozzle band heater Thermocouple mounting diagram (1) Nozzle band heater (2) Thermocouple (3) Nozzle. Screw in the nozzle, heat it to the same temperature, and tighten it according to the thread diameter and tightening torques of screws (or bolts) described in 7.3. Warning: Note that pressure may be produced in the barrel when processing a thermosensitive material or wet PA! Do not stand in front of the nozzle when unscrewing it! Please wear a face shield and safety gloves before working on a heated barrel! Use solvents (inflammable, with harmful steam) only under special circumstances. Information: Protect a barrel that has received surface anti-wear treatment from collision and strike! Prevent it from falling. Please do not use a hard object for cleaning. Please do not use the plastic residue after ignition on a soldering lamp (otherwise it may cause hardness loss or distortion deformation).

1. 1. Please heat the barrel (to specified temperature).

2. 2. Set low injection flow and pressure.

3. 3. Purge and empty the barrel.

4. 4. Turn off the nozzle heater.

5. 5. Dismount the nozzle band heater.

6. 6. Unscrew the thermocouple.

7. 7. Unscrew the nozzle (right-hand thread).

7.12.2 Mounting and dismounting of the front barrel

Steps of mounting the front barrel:

Figure 7.12.2.1 Front barrel mounting diagram (1) Bolt (3) Screw head (2) Front barrel (4) Charging barrel. Steps of dismounting the front barrel:

1. 1. Check fixing bolts (configured according to the machine standards of the company) to see that they are grade 12.9 high-quality bolts, and evenly apply high temperature-resistant lubricating grease (such as MoS2) on the thread surface of bolts.

2. 2. Fix the front barrel on the barrel via bolts (the thermocouple mounting hole on the front barrel must have an upward angle of 45° on the back), and tighten them symmetrically. Use a suitable wrench, better a torque wrench.

3. 3. Mounting of band heaters and thermocouple. Heat them to the set temperature, and tighten them according to the thread diameter and tightening torques of screws (or bolts) described in 7.3 about 10 min later.

• 1. Set machine heating temperature to resin processing temperature, start heating, and cut off the power supply of the machine about 10 min after reaching the set temperature.

• 2. Unloosen bolts in diagonal order.

• 3. Dismount band heaters and temperature detection thermocouples on the front barrel and the nozzle. Wrench.

• 4. Completely unloosen and remove the fixing bolts of the front barrel. Provide adequate protection, and prevent the front barrel from falling after removal of the last bolt.

• 5. Take off the front barrel.

7.12.3 Removal and installation of screws

The barrel module related to the thermoplastics process is described below. Where the resin produced by the machine is PC, PVC, PA, or ABS, dismounting is allowed only after the machine has been cleaned using PS, PE, PP, or other special-purpose cleaners. 7.12.3.1 Articles to be prepared for removing screws: - Four or five wooden or steel poles (diameter < screw diameter) X (length > injection stroke). - Four or five segments of squared timber (100mmx300mm). - Clamp. - Waste cotton or cloth. 7.12.3.2 Preparations for removing screws:

Detailed procedures for screw removal, screw head operations, and reinstallation are described in the subsections below.

1. 1. Heat the barrel to approximately the maximum temperature of the resin used (the temperature can be raised by 50°C for the nozzle and the second area to make convenience for removing the fixing screws of the front barrel).

2. 2. Close the blanking port, and empty the barrel.

3. 3. Cut off the power supply of the band heater.

4. 4. Dismount the blanking plate corresponding to the injection unit.

5. 5. Retract screws to leave sufficient removal space.

6. 6. Remove band heaters on the nozzle and the front barrel.

7. 7. Remove six Half-type locking screws, take off the Half-type structure, dismantle other parts connected with screws, and separate Half-type fixing bolts from other bolts to avoid confusion.

8. 8. Perform suck-back action to disengage screws from the coupling spindle, as illustrated below.

7.12.3.3 Screw removal procedure

Screw removal procedure is performed in the following steps. Ensure all safety precautions are followed.

7.12.3.3.a Screw removal steps 1-2

7.12.3.3 Screw removal: Step 1 of screw removal: Perform integral retraction to the end, remove the mold and the locating ring, and adjust mold thickness and mold opening to the maximum. Figure 7.12.3.3.1 Diagram of relative positions of various parts before screw removal. Step 2 of screw removal: (1) Remove the two fixing bolts close to the thrust block direction (① in Figure 7.12.3.3.2), unloosen the adjusting swivel nuts on the outside of these fixing bolts (② in Figure 7.12.3.3.2), and unscrew left and right adjusting bolts (③ in Figure 7.12.3.3.2); Figure 7.12.3.3.2 Diagram of injection bracket removal. ① Fixing bolt, Adjusting swivel nut, Adjusting bolt. (2) Remove the piston rod hanger screws of the integral movable cylinder on the front die plate. (3) Perform integral advance action to retract the integral movable cylinder. Figure 7.12.3.3.3 Diagram of performing integral advance action. (4) Place wood between the front die plate and the piston rod hanger of the integral movable cylinder. (5) Perform integral retraction action to retract the injection blend to a suitable position. Figure 7.12.3.3.4 Diagram of padding the integral movable hanger with wood for integral retraction.

7.12.3.3.b Screw removal steps 3-4

Step 3 of screw removal: (1) Cut off power supply, and remove band heaters on the nozzle and the front barrel. (2) Remove the fixing screws of the front barrel (refer to the steps in 7.11.2). Step 4 of screw removal: Removal of the front barrel and the nozzle (refer to the steps in 7.11.2). Figure 7.12.3.3.5 Diagram of removing the front barrel and the nozzle. Nozzle Front barrel, Bolt Band heater, Fixing screws of the integral movable hanger.

7.12.3.3.c Screw removal step 5

Step 5 of screw removal: removal of screws and screw head unit. Confirm that all the steps in 7.12.3.2 have been completed, and that screws have been separated from the apical axis (if not, injection and suck-back actions can be performed to separate them): (1) Use a wooden or steel pole in suitable length whose outer diameter is slightly less than screw diameter (one of the articles prepared in 7.12.3.1), place it between the micro-end face of the screw and the thrust block of the sled, and hold the wooden or steel pole with a clamp (instead of a hand). Figure 7.12.3.3.6 Diagram of wooden pole at the screw-tail point. (2) Jog the injection action key to push screws forward, and remove the clamp at the same time. (3) After the whole-course advance of injection action, jog injection and suck-back actions for the whole-course retraction of the thrust block. (4) Pad with the second wooden or steel pole. Repeat steps (1)~(3) until the screw is largely exposed out of the barrel. (5) Pull out the screw towards the front die plate direction, and hoist it out. Figure 7.12.3.3.7 Diagram of screw removal. Warning: Please wear a face shield and safety gloves before working on a heated barrel! Screws just removed from the barrel are still hot, and may not be directly touched by hand. After a large screw is ejected by 1/2 length, hold it up with the slings, hang it with the hook, fully disengage it, and hoist it out. Place screws on a wooden block or stand to prevent damage. Vertically hang screws to prevent bending deformation if it is not to be used for a long time. Information: Protect a barrel module that has received surface anti-wear treatment from collision and strike! Prevent it from falling. Please do not use a hard object for cleaning. Please do not use the plastic residue after ignition on a soldering lamp (otherwise it may cause hardness loss or distortion deformation).

7.12.3.4 Screw head removal and mounting

7.12.3.4 Screw head removal: Removal method: Operate the wrench on the screw-tail (keyway) bush (#4 in Figure 7.12.3.4.1). Use a special-purpose wrench to hitch the screw head (#1 in Figure 7.12.3.4.1). Face the screw, and rotate the wrench clockwise to loosen and disengage it. Note in particular that the screw has a left-hand thread. Figure 7.12.3.4.1 Diagram of screws and related parts (1) Screw head (2) Check ring (3) Thrust ring (4) Screw (5) Special-purpose wrench for screw heads. 7.12.3.5 Mounting of screw head: Removal method (Mounting method): Apply a thin layer of high temperature-resistant lubricating grease (such as MoS2) on the thread of the cleaned screw head (#1 in Figure 7.11.3.4.1). Mount the check ring (#2 in Figure 7.11.3.4.1) and the thrust ring (#3 in Figure 7.11.3.4.1) on the screw head in succession. Make sure to mount them in the right direction, as the check ring has a specified direction on some machine models. Screw in the screw head (#4 in Figure 7.11.3.4.1). Operate the handle on the screw-tail (keyway) bush. Use a special-purpose wrench for screw heads (#5 in Figure 7.11.3.4.1) to hitch the screw head. Face the screw, and rotate the wrench and the handle counterclockwise to tighten it. Figure 7.12.3.4.1 Diagram of screws and wrench.

7.12.3.6 Screw reinstallation

7.12.3.6 Mounting of screws: Mounting of screws: Mount screws on the machine by steps opposite to the steps for dismounting them in 7.12.3.3.

7.12.4 Dismounting and mounting of the barrel (the barrel and screws together)

7.12.4.1 Barrel dismounting: Step 1 of barrel dismounting: Warning: Please wear a face shield and safety gloves before working on a heated barrel (such as dismounting band heaters). Perform integral retraction to the end. Figure 7.12.4.1.1 Diagram of performing integral retraction to the end. Step 2 of barrel dismounting: Dismantle the barrel safety guard, the hopper, all band heaters, electric devices connected with the barrel, and other relevant parts and devices. Figure 7.12.4.1.2 Diagram of dismounting barrel-related auxiliary devices. Step 3 of barrel dismounting:

Additional barrel dismounting and mounting procedures are described in the subsections below.

1. 1. Remove the two fixing bolts close to the thrust block direction (#1 in Figure 7.12.4.1.3), unloosen the adjusting swivel nuts on the outside of these fixing bolts (#2 in Figure 7.12.4.1.3), and unscrew left and right adjusting bolts (#3 in Figure 7.12.4.1.3), as illustrated below; Figure 7.12.4.1.3 Diagram of injection bracket removal.

2. 2. Dismount the piston rod hanger screws of the integral movable cylinder on the front die plate; Figure 7.12.4.1.4 Diagram of dismounting the fixing bolts of the integral movable hanger.

3. 3. Perform integral advance action to retract the integral movable cylinder.

4. 4. Place wood between the front die plate and the piston rod hanger of the integral movable cylinder. Figure 7.12.4.1.5 Diagram of integral sled retraction.

7.12.4.1.5 Barrel dismounting steps 4-5

Step 4 of barrel dismounting: (5) Perform integral retraction action, retract the injection blend to a suitable position, and hang the slings on the barrel. Temporarily hoist the barrel, as illustrated below. Figure 7.12.4.1.6 Diagram of hoisting the barrel after sled retraction. Step 5 of barrel dismounting: Reconfirm that all the steps in 7.12.3.2 have been completed, and that screws have been separated from the apical axis (the clearance between them should be able to ensure that the lock nuts of the barrel can be removed; if not, injection and suck-back actions can be performed to increase the clearance). Remove the lock nuts of the barrel. Figure 7.12.4.1.7 Diagram of removing the lock nuts of the barrel.

7.12.4.1.6 Barrel dismounting step 6 and mounting

Step 6 of barrel dismounting: Pull the barrel out of the injection blend towards the front die plate direction, and hoist it out according to the following steps: (1) Insert a wooden pole between the thrust block and the rear end of the barrel as illustrated, and make sure to clamp the wooden pole. Do not directly hold it up with a hand. Figure 7.12.4.1.8 Diagram of pushing the barrel forward with the thrust block. (2) Make sure to reduce injection speed and pressure, perform injection action, and push and press the barrel forward. (3) After the whole-course advance of the barrel, jog suck-back action for the whole-course retraction of the thrust block again. (4) Repeat steps (1)~(3). (5) After roughly one half of the fitting length between the barrel and the injection blend is pushed out of the injection blend, slightly adjust lifting height. (6) Repeat steps (1)~(3) to fully disengage the barrel from the injection blend. (7) Slowly lift it to a position where follow-up work is not interfered with. Figure 7.12.4.1.9 Diagram of hoisting out the machine after barrel ejection. Caution: Where the space between the injection blend and the front die plate is small, step 2 can be conducted to suitably retract the injection blend. The barrel just disengaged from the injection blend is still hot on the surface, and may not be directly touched by hand. 7.12.4.2 Barrel mounting: Mount the barrel by steps opposite to the steps for dismounting it in 7.12.4.1.

7.12.5 Cleaning and detection of the barrel and screws

When necessary, remove screws for cleaning and detection. For steps of dismounting the barrel and screws, refer to relevant contents in 7.12.1~7.12.4. Clean the materials to be prepared: Besides relevant tools, prepare the following materials as well: - About four or five wooden blocks (diameter < screw diameter) X (length > injection stroke); - About four or five square wooden blocks (100mm×100mm×300mm). - Pinchers; - Waste cotton; - One long wooden or bamboo pole (diameter < screw diameter) X (length > barrel length); - Incombustible solvent (such as trichloroethylene); - Brass rod and brass brush. Description: Screws dismounted from the machine should be placed on wooden blocks (more than two wooden blocks) to prevent damage. Caution: A heated barrel poses burn risk to the operator. It is required to wear personal protective equipment (protective clothing, face shield, safety shoes, safety gloves, protective mask). 7.12.5.1 Screw cleaning: Clean screws:

Figure 7.12.5.1.1 Diagram of screw module. Screw head, Check ring, Sealing ring, Screw. Caution: Do not damage the surface of parts in cleaning. Apply a layer of high temperature-resistant lubricating grease (such as MoS2) on thread before mounting the screw head. In the case of solvent cleaning, protection measures should be taken to prevent skin exposure to smoke. 7.12.5.2 Screw detection: Relevant detection contents: Damage; Coating wear; Thread integrity (screw body); Intactness of check ring and thrust ring surface. Damage to the above components may cause the reverse flow of the material during injection, thus affecting product quality. 7.12.5.3 Barrel cleaning: Barrel cleaning: (1) Use the brass brush to remove resinous deposits attached on the inner surface of the barrel. (2) After barrel temperature drops by 30~50°C, wet waste cotton with a solvent, cover the end face of a wooden pole or long bamboo pole with waste cotton, and insert it into the barrel to clean its inner surface. (3) Replace the waste cotton used for cleaning several times in the cleaning process. Caution: It is also necessary to clean the front barrel and the nozzle, especially where they fit or contact with other parts. Caution must be taken in cleaning to prevent damage to the surface of parts, otherwise the parts may be rendered unavailable for normal use. 7.12.5.4 Barrel detection: Barrel detection: Refer to the following diagram, and check the inner surface of the barrel to ensure that it has been cleaned up. Observe its inner surface to see if there are scratches or other damages. Figure 7.12.5.4.1 Diagram of the barrel module. (1) Nozzle (2) Front barrel (3) Charging barrel (4) Lock nuts of the barrel.

1. 1. Wipe clean screw body with waste cotton, so as to remove most resinous deposits.

2. 2. Remove residual resinous deposits with the brass brush. Or first heat the resinous deposits on screws with a combustor or similar device for a while, and then remove them with the brass brush or waste cotton.

3. 3. Clean the screw head, the check ring, and the thrust ring using the same method as that used for cleaning screw body. Clean the thread and screw body on the screw head with the brass brush as well.

4. 4. After screws cool down, use a non-inflammable solution to wipe clean all the oils.

7.12.6 Mounting of thermocouple

7.11.6.1 Replace the thermocouple on the barrel: Dismount the thermocouple:

Mounting of thermocouple: 1. Please verify the model, and unpack the new thermocouple after confirmation. 2. Please thoroughly clean the thermocouple hole (inaccurate measurement!). 3. Please insert the thermocouple into the hole until its apex leans against the bottom, properly adjust the screwed connector bush, and clamp it onto the bayonet. 4. Please route the wire along the heating path, connect the thermocouple wire to the terminal in the terminal box, and tighten it. 5. Please properly reinstall the protective cap on the barrel module. Figure 7.12.6.1.1 Diagram of mounting barrel thermocouple. (1) Thread socket on the thermocouple (2) Thermocouple temperature sensor (3) Fixing thread hole of thermocouple (4) Charging barrel. In case of a fault or thermocouple cable disconnection when opening the band heater, a warning prompt will be displayed on the controller screen. 7.12.6.2 Replace the thermocouple on the nozzle: Dismount the thermocouple: 1. Please turn off the master switch on the machine first for the sake of safety. 2. Please loosen the thermocouple on the nozzle, and take it out. 3. Please open the heater terminal box, loosen the corresponding terminal, and take out the thermocouple wire. Mounting of thermocouple: 1. Please verify the model, and unpack the new thermocouple after confirmation. 2. Please thoroughly clean the thermocouple hole (inaccurate measurement!). 3. Please insert the thermocouple into the nozzle, and tighten it. 4. Please route the wire along the heating path, connect the thermocouple wire to the terminal in the terminal box, tighten it, and fix it along the way. Figure 7.12.6.2.1 Diagram of mounting nozzle thermocouple (1) Nozzle band heater (2) Thermocouple (3) Nozzle. Caution: Please note that the thermocouple is located at the hexagon position of the nozzle wrench, so dismount the thermocouple first before mounting/dismounting the nozzle.

1. 1. Turn off the master switch on the machine first for the sake of safety.

2. 2. Take off the guard of the blanking barrel module.

3. 3. Please screw out the screwed connector bush on the thermocouple, and take it out of the hole.

4. 4. Please unloosen the corresponding thermocouple terminal in the heater terminal box, and take out the wire.

7.12.7 Replace band heaters

7.12.7.1 Replace band heaters on the barrel: Dismount band heaters:

Figure 7.12.7.1 Diagram of barrel and guard (1) Barrel guard (outer shield) (2) Barrel guard (upper shield) (3) Band heater (4) Thermocouple (5) Charging barrel. Information: Mount band heaters: A newly mounted band heater must be tightened again after initial heating. An incorrectly locked band heater leads to a higher energy demand, and delays heating action. 7.12.7.2 Replacement of the nozzle band heater: Replace the nozzle band heater: 1. Please turn off the master switch on the machine for the sake of safety. 2. Dismantle the power wire of the nozzle band heater. 3. Unfasten the fixing screws of the nozzle band heater. 4. Dismount the nozzle band heater. 5. Mount a new nozzle band heater. 6. Set the screws of the nozzle band heater on the sides. Tighten them. Figure 7.12.7.2 Diagram of mounting the nozzle band heater (1) Nozzle band heater (2) Thermocouple (3) Nozzle. Information: A newly mounted band heater must be tightened again after initial heating. An incorrectly locked band heater leads to a higher energy demand, and delays heating action.

1. 1. Cut off the power supply of the machine.

2. 2. Remove the screws on the barrel module (upper and lower) guard.

3. 3. Take off the guard of the blanking barrel module.

4. 4. Screw out the thread socket on the thermocouple. Pull the thermocouple out of the hole.

5. 5. Loosen the power wire on the heater terminal. Loosen the heater connecting wire on the terminal strip.

6. 6. Unloosen the fixing screws of band heaters. Move out band heaters towards the front end of the barrel (nozzle direction).

7. 7. For the purpose of replacing a single band heater, first remove its fixing screws, then disengage it with hands, and finally take it off for replacement.

7.13.1 Adjustment of the mechanical gliding feet of a small-sized machine

Method of adjusting the mechanical gliding feet of a small-sized machine: Adjustable sliders are mounted below the moving die plate of a small-sized machine. Before adjustment, properly regulate the mold-move guide rails of the machine’s clamping part to horizontal state, unload the mold, and press the mold closing key to stretch the linkage. Loosen the lock nuts on the adjustment column, measure the distance between the tie bars and the guide rails using an outside micrometer, and use a wrench to rotate the adjustment column based on measurement results until the tie bars and the guide rails are parallel. Press the mold adjustment key to observe whether system pressure and mold adjustment action are smooth upon mold adjustment. After adjustment, load the mold to try again until achieving satisfactory results. Figure 7.13.1 Diagram of the gliding feet of the moving die plate of a small-sized machine (1) Adjustment column (2) Lock nut.

7.13.2 Hydraulically supported gliding feet of large and medium-sized machines

The moving die plate of large and medium-sized machines adopts a hydraulically supported gliding feet system, supported by two groups of gliding feet with the same supporting pressure.

7.13.2.1 System overview and pressure adjustment

Gliding feet support system of the moving die plate of large and medium-sized machines: The moving die plate of large and medium-sized machines adopts a hydraulically supported gliding feet system (see Figure 7.13.2), and is supported by two groups of gliding feet with the same supporting pressure. This design minimizes the bending moment produced by the moving die plate in tie bars, always keeps tie bars in horizontal state, and improves the working performance of mold closing components. It is highly necessary to achieve the optimal supporting pressure and maintain a certain charge pressure. Figure 7.13.2 Diagram of the gliding feet of the moving die plate of large and medium-sized machines. (1) Accumulator (3) Solenoid directional valve (2) Pressure relay (4) Manual relief valve. Adjustment of supporting pressure: To adjust supporting pressure is to adjust the pressure of the pressure relay, generally within the range of 2~6 MPa. The specific adjustment will be made within this range according to mold weight until tie bars become horizontal. The pressure relay and the pressure relief valve are mounted on the non-operating side of the moving die plate, while pressure gauges are mounted on its operating side. Rotating the adjustment knob of the pressure relay clockwise raises the pressure. Where the pressure becomes too high, it can be lowered below the required pressure by rotating the adjustment knob of the pressure relay counterclockwise and loosening the adjustment handle of the accumulator’s pressure relief valve. After that, the required pressure can be achieved by suitably tightening the adjustment handle of the pressure relief valve again and rotating the adjustment knob of the pressure relay. Caution: This pressure has been properly adjusted before delivery of the machine, and should not be arbitrarily altered unless in special circumstances.

7.13.2.2 Accumulator charging and safety

Charging of accumulator: When charging the hydraulic support system, loosen the adjustment handle of the pressure relief valve, open the upper-end cover of the accumulator, load charge pressure, and connect high-pressure nitrogen. After that, slowly turn on the charge pressure switch, and wait until reaching the specified gas pressure (2~3 MPa for this machine). Where the pressure becomes too high, screw off the venting plug until the gas pressure drops to the specified value. Regularly check the charge pressure of the accumulator in the service process. For the connection method of the accumulator, please refer to Chapter 5. Warning: When the bladder pressure of the accumulator fails to reach or exceeds the specified charge pressure, the hydraulic support system of the moving die plate will be invalidated, causing inconvenience to mold opening/closing action. To prevent explosion, the accumulator must be charged with nitrogen above 99.995% in purity. It is prohibited to use other gases.

8.1.1 Names and applications of common resins

Popular name, abbreviation, Scientific name in Chinese, Scientific name in English, and list of Chinese and English names for plastic raw materials: Table 8.1.1.1 Chinese English comparison table.

8.1.2 Table of non-crystalline and semi-crystalline plastics

Table of noncrystalline and semicrystalline plastics: Table 8.1.2.1 Amorphous and semi crystalline plastics.

8.1.3 Drying of raw materials

Table 8.1.3.1 Raw material drying table. A: hot air dryer, D: dehumidifier, *: no need of drying for raw materials, NH: non-hygroscopic raw material. The data recommended by the raw material supplier should be checked.

8.3.1 Removal of clogging and cold slugs

Processing problems: Depending on the material type and mobility of particles, inadequate pre-drying and wrong temperature control may cause very serious processing problems! Danger: Plastics melting due to high temperature and poor control poses the dangers of serious injuries and combustion! Attention should be paid to the processing conditions specified by the material manufacturer! All faults related to feed clogging or nozzle freezing must be cleared by trained professionals. Protective clothing and face shield should be worn before dealing with the nozzle or the barrel module. Barriers should be erected to prevent unnecessary access! Example:

Plug feeding port: The problem of blocking of the charging opening can be basically solved through oscillation around feed support. Has this method failed: Please note the values stated in the process sheet provided by the material manufacturer, as a temperature lower than glass transition temperature weakens melting effect. Move the feed hopper on the slide bar. Monitor the feed opening, and empty it if possible (vacuum cleaner). Please do not use any hard or fragile article when emptying the feed opening. Be sure not to clean screws in rotation. Use a mixer in the feed hopper in case of continuous problems. Purchase from an accessory manufacturer. Remove cold slugs: Detect nozzle heating temperature (there may be a transient rise). Purge the barrel by pressing the “Cleaning” key. Has this method failed: Lower the temperature of the barrel module, and dismount and clean the nozzle head. Clean the venting outlet of the barrel: Pay special attention to the venting barrel. Be sure not to clean screws in rotation. Remove material residues using a scraper. Dismount and clean the funnel at the venting outlet of the barrel. Self-locking nozzle: Be careful with the self-locking nozzle, as gas may be connected behind it. Always purge first and slightly pull screws back when dismounting the self-locking nozzle or the nozzle head. Keep the self-locking nozzle in stable open state (applicable only to hydraulic and pneumatic nozzles). Lower the temperature of the barrel module.

• (1) Material feed may be clogged due to blocking of the charging opening.

• (2) Reducing nozzle temperature may produce cold slugs at the nozzle orifice.

• (3) The material in the barrel may be overheated in the case of interrupted operation if temperature is not lowered. Plastics melting due to poor control poses the danger of gas formation and serious explosion!

8.3.2 Poor quality of plastic products and solutions

Causes: Some defects in moulding are related to machine performance, mold design, or raw material properties. Beyond that, most problems can be solved through adjusting operating conditions. Adjustment requirements: After changing one factor, the results of such change should be examined before moving on to another factor (such as pressure, speed, temperature, time, and position). An observation period should be reserved after adjustment, as the results count only after the operations have become balanced and stable. The results of pressure change are available after one or two molds, but it takes 10 min to obtain the stable results of time and temperature change. It is necessary to get familiar with the possible causes of defects and the factors to be preferentially adjusted. Described below are all kinds of defects and their possible causes and countermeasures. Some defects are attributable to single causes, while others may relate to multiple factors.

Unfinished products

8.3.2.1 Shrinkage

Finished product sticking

8.3.2.2 Runner (gate) sticking

Burr and flashing

8.3.2.3 Finished product fracture in mold opening or ejection

Joint line

8.3.2.4 Flow line

Splay, and gas mark

Poor gloss on finished product surface

8.3.2.5 Deformed finished product

Pores in finished product

8.3.2.6 Black spots

Black streaks

Stable cycle

As far as the above problems are concerned, their causes and countermeasures are mostly related to cycle stability. This is because the proper plasticization of plastics in the barrel and the maintenance of a constant mold temperature are both the results of heat balance. That is, in the entire continuous operation, the plastics in the barrel receive the friction heat generated by screw rotation, and the heater band is heated. In particular, the heating of heater band is related to heating time, and its heat is sent into the mold together with plastics. Mold heat is derived from plastics and hot water. It is lost to finished products, vaporized in the air, or taken away by cooling water. To keep a constant barrel or mold temperature, it is necessary to maintain an inlet/outlet heat balance, which requires a constant cycle time. When the cycle becomes shorter and shorter, causing inlet heat to fall short of outlet heat, the heat in the barrel will be insufficient to plasticize the raw materials. In contrast, inlet heat is more than outlet heat in the mold, which causes mold temperature to rise continuously, and vice versa. Thus, it is necessary to maintain a stable cycle time and avoid significant speed fluctuations in any moulding operation, especially manual insert operation. Given other conditions: A shorter cycle will result in short shot, shrinkage, deformation, and sticking. A longer cycle will cause flash, burr, sticking, deformation, raw material overheat, or even burn mark, and the residual coke charge may damage the mold. The overheated raw materials in the barrel may corrode the barrel, or produce black specs or streaks in finished products.

8.3.2.7 Use of recycled materials, slipping of screws (unable to feed), and glue leakage through the nozzle (running fluid)

Use of recycled materials: Note that the hardness of recycled materials must be the same as that of new materials, and that the most ideal recycling method consists of continuous crushing, drying, and processing. Do not store recycled materials for too long. Keep crushed particles close to new ones. Refrain from using recycled materials when there are special requirements for the performance of finished products, as repeated recycling of resin will degrade the properties of finished products. Slipping of screws (unable to feed): Table 8.3.2.7.1 Fault causes and treatment methods 15. Glue leakage through the nozzle (running fluid): Table 8.3.2.7.2 Fault causes and treatment methods 16.

9.2.1 Simple calculation method

Calculation of clamping force: For a specific application, one difficulty faced by plastic injection moulding is how to determine the minimum clamping force. The clamping mechanism must ensure that the two halves of the mold are closely clamped together in injection moulding and holding processes. There are numerous empirical values for reference with regard to each kind or type of thermoplastic raw materials, but usually they are not enough. A simple method of calculating clamping force is to multiply the total projected area by the empirical value of mean mold cavity pressure. For instance, when the projected area is 20 in² and the mold cavity pressure (securing force) required by PS is 2.5 t/in², clamping force can be calculated to be 20×2.5=50 t. This method, however, applies only to rare circumstances. Most technologists have found this empirical formula to be highly inapplicable in the case of thin-wall product moulding, long flow path, high viscosity, or their combinations.

9.2.2 Scientific approach and projected area

According to the scientific approach, the first step is to determine the projected area bearing injection pressure. The projected area is the area projected by the cavity, runner system, gate, and any raw material runner under mold slider/locking heel reaction force in the direction parallel to clamping force direction. Where one product is behind another (such as mold stacking), there is no need to increase clamping force. The actual required clamping force is the product of the pressure built by raw materials and the total projected area. For thin-wall, long-flow path products, the pressure built by raw materials can be very high, as the pressure loss from the gate to the end must be counted. Taking the above mold as an example, the product is 2 inches in width, 9 inches in length, and 0.05 inches in thickness. The gate is at one end. The raw material used is glass fiber reinforced PC. The raw material pressure at the gate is 17,000 psi, and that at pack end is 3,000 psi, so the mean raw material pressure of the cavity is (17,000+3,000)/2 = 10,000 psi. The required clamping force is 10,000 psi*20 in²/2,000 = 100 t (US ton). In mold manufacturing, computer simulation can be employed to estimate raw material pressure, and further obtain a pretty precise clamping force. Where a mold has been built up, raw material pressure can be measured using the cavity pressure sensor, and estimated through pressure difference analysis on the runner in the mold.