1.4.1 Icon signs

For the purpose of this Manual, the following denominations and signs are used to express particularly important information:

Danger

Posing immediate threats. Death caused by serious injuries.

Warnings

Possible danger. Possible death or serious injuries.

Caution

Minor danger. Mild trauma.

Caution

Circumstances posing possible injuries. Injuries caused by the machine and surrounding environment.

Information

No danger, or no consequence of personal injuries or property losses.

1.4.2 Other icons

Another two icons are also frequently used in this Manual: Description of icons, Number of points marked, Actions required to be taken by the operator.

1.4.3 Warning labels

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

• 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.

  

• Touching 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 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.

  

• 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.

  

• 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.

  

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

  

• Danger areas: (1) Main power switch of the electrical box.

  

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

  

• 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. Areas: (1) Nozzle head. (2) Clamping mechanism. (3) Mold area.

  

• 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.

  

• 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.

  

• 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.

1.4.4 Instruction labels

• 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.

  

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

  

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

  

• 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 offers information about the company and the equipment.

  

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

  

• 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.

  
• 

• The mold to be installed may not be used beyond this range.

  

• 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.

  

• 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.

• Front safety door limit switches using as electrical pressure protection (-SQ42)

• 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 used for electrical protection. For its control principle, please refer to the electrical schematic.

• Back safety door limit switches, using as electrical protection (-1SQ42)

• 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.

• Long Press Unlock

• 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 (optional) (-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 (optional) (-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 (optional) (-SB1)

  Please confirm equipment and personal safety before resetting.

• Indicator sign of ejector advance pressure gauge (optional) (-B3)

  As the device displaying the actual pressure of ejection or ejector pin action, it is usually effective upon linkage action.

• Indicator sign of sequence valve pressure gauge (optional) (-B7)

  It is the device displaying the actual pressure of sequence valve action.

• Indicator sign of auxiliary pressure gauge in mold adjustment (optional) (-B10)

  It is the device displaying the actual pressure of the auxiliary hydraulic circuit in mold adjustment action.

• It is prohibited to use dirty oil, waste oil, or oil contaminated by water, steam, dirt, or sun exposure.

• It is prohibited to use dirty oil, waste oil, or oil contaminated by water, steam, dirt, or sun exposure.

• It is prohibited to use dirty oil, waste oil, or oil contaminated by water, steam, dirt, or sun exposure.

• 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.

  

• 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.

  

• 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.

• The lubricating oil use for system must be provided by manufacturer. We would not be responsible for any bad results caused by adopting other lubricating oil.

  

• The lubricating oil use for system must be provided by manufacturer. We would not be responsible for any bad results caused by adopting other lubricating oil.

  

• 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.

1.4.5 Schematic labels

• 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. For detailed steps about machine level adjustment, please refer to 4.3 of this Manual. (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 (threephase) (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 repair the machine (such as safety shoes, safety gloves, and face shield). Please pay attention to local safety regulations on the operation safety of injection moulding machine!

1.5.2 Principles and specifications to be complied with

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 the 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

This Manual must always be kept in the electrical box of the machine for unexpected needs! As a supplement to this Manual, it is also required to note and comply with laws and regulations on accidental protection and environmental protection as well as other binding rules!

1.5.4 Requirements for the operator and 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 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

The following categories describe special hazard types associated with the injection moulding machine. Personnel must be aware of and prepared for each type.

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 temperature, 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, 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 hazards

High-pressure explosion: 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 hightemperature barrel, and cause explosion as a result of continuous high temperature. The user is duty-bound to control and avoid such circumstances.

1.6.5 Electrical hazards

Moulding equipment uses high-ampere current under high voltage. Power requirements are marked on 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

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 fields may cause harm to pregnant women or persons who have received a medical implant. They usually emerge on the following occasions: Supply cables, Main power connections, Transformer and driver shell, Motor (servo motor), Magnetic die plate mounted on the machine, Permanent magnets (such as the fixators of sliding gates). Persons wearing an active implant (such as 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.

1.6.8 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 table1.6.8.1.

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 with 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. Warnings: When nitrogen is used during production, oxygen content must be constantly checked before working on site.

1.6.10 Slipping/tripping/falling hazards

Warnings: 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.

1.8.1 General safety rules for operation

Caution: The curb window and the blanking plate should be kept clean. An operator must be certified to install and debug the machine and the mold. The lifting force of the hoisting equipment should be sufficient when handling the mold. It is absolutely prohibited to dismount the protective blanking plate of the machine. This is especially so when the machine is running. Metals should be strictly prohibited from entering the hopper or barrel, otherwise the barrel or screws may be damaged. It is required to stop the motor and depressurize the system before dismounting hydraulic components! The main power should be cut off before checking the electrical circuit or opening the electrical box. There may be high-temperature spots in the mold area, so personal protection should be taken before entering this area. A high-temperature warning label should be pasted on the hightemperature mold!

1.8.2 Emergency procedures and pressure relief

In case of accidental interruption of the machine during automatic running, there may be residual high pressure in the barrel or mold. Thus, before troubleshooting, it is necessary to first conduct suck-back and other necessary pressure relief operations, and then dissociate the nozzle from the mold through injection blend retraction. The safety gate can be opened for troubleshooting in the mold area only after safety is confirmed. The master switch must be cut off if the machine is to be put out of service for a long time. It is not allowed to arbitrarily replace or dismount any part on the machine without the approval of the company.

1.8.3 Operator body protection during operation

Safety tips: A safe distance should be kept during operation, so that the hands (limbs) of the operator would not enter the safety guard or touch any moving component. Figure1.8.1 Diagram of preventing the hands (limbs) of the operator from touching any moving component for injection. Figure1.8.2 Diagram of preventing the hands (limbs) of the operator from touching any moving component for clamping. To avoid injuries, it is prohibited to insert your hands into the blanking opening of the product during machine running. Figure1.8.3 Diagram of preventing the hands of the operator from entering the blanking opening of the product. It is absolutely prohibited to insert your hands or fingers into the blanking opening! Figure 1.8.4 Diagram of preventing the hands and fingers of the operator from entering the blanking opening.

1.8.4 Barrel safety and access restrictions

It is not allowed to tear off the sign pasted. The heated barrel area is protected by a safety guard during operation, but its temperature is still very high, so no touching is allowed. No sundries may be left on the barrel safety guard. Where the barrel safety guard needs to be dismounted for the convenience of repair, the power source should be first cut off by a professional. A clamping linkage that is not completely locked stores energy, so the die plate may move accidentally. To prevent accidents, mold opening action should be performed to confirm that the mold has been opened before opening the safety gate. Where a machine supports manual ejection and ejector pin function after the safety gate is opened, it is prohibited to adjust the internal parameters of the machine. It is required to make sure that the action speeds of ejection and ejector pin are ≤10 mm/s during holding action. The operator and servicemen may enter the working area only via the designated access position. The user is duty-bound to keep the cleanness of the ground, the access position, and the working position.

1.9.1 Protective cover or protective door

Figure 1.9.1.1 Schematic diagram of guards of the machine. 1 Fixed top protective cover (medium and large-scale mode machine without this cover). 2 Movable protective gate (Safety gate). 3 Movable top cover (Middle and Large mode without this cover). 4 Nozzle protective cover. 5 Injection unit protective cover (The structure of the injection unit protective cover will be different according to the model). 6 Fixed protective cover of clamping unit. 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 machine). 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). Warnings: Operations with the protective cover removed are not allowed.

1.9.2 Mechanical safety mechanism

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. Schematic diagram of clamping unit: 1 The briquetting for safety sensor, 2 Safety bar, 3 The cable of safety brake block. 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.

1.9.3 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

The hydraulic safety system includes: (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 safety valve, and then the 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 hydraulic system and protects the operator and hydraulic components, such as oil pump and pipe fittings. Caution: Do not adjust the system safety valve under any circumstances.

1.9.5 Electromagnetic lock device on safety door

The operation side safety door is equipped with an electromagnetic lock device. When the machine is in the normal state, the electromagnetic lock device is locked. When need to open the safety door, you need to keep pressing the unlock button of the machine to open the door. The unlock button will not work in the following states. (Some models have no unlock button, except for the following states, the safety door can be opened directly). The device is not energized. The device is energized and in fully automatic mode. The device is energized in semi-automatic mode, and in semiautomatic cycle time. Equipment power, in manual mode and mode adjustment mode, open and close the mould is doing the action. Caution: When the electromagnetic locks are in operation, please do not force to open the doors, which will lead to malfunction otherwise. Please note that never apply any unreasonable external force to the safety doors. In unpowered condition, the electromagnetic locks are in operation, the safety doors are locked. Maintenance will have to wait until the doors are open, please use the special key to turn the electromagnetic lock knob to the [UNLOCK] position. At this time, the electromagnetic lock is in an invalid state and the safety door can be opened. After opening the safety door, be sure to turn the electromagnetic lock knob back to the [LOCK] position, otherwise the electromagnetic lock will not be able to protect it, which may cause personal injury or equipment damage.

1.9.6 Auxiliary equipment

If the user of this machine needs to equip auxiliary equipment, only when such equipment is installed according to EN ISO20430 can this machine be operated. The Company is only responsible for the interface interaction of self-designed injection machine and auxiliary equipment. If the user removes the auxiliary equipment, the EN ISO20430-compliant guard or safety device should be reinstalled.

1.9.7 Loading platform and auxiliary device

The Company strongly recommends that the user should load materials with 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 the technical support for loading platform, as shown in Figure 1.9.6.1. Caution: 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 the 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.

2.2.1 Grounding and power line specifications

Grounding. Specifications of power lines for various machine types: See the Table 2.2.1 below for the specifications of distribution board, power line and grounding wire for various machine types. Table 2.2.1 Power supply parameters of various machine types. Danger High voltage: Exposure to dangerous voltage may lead to the most severe trauma and death. The power line connector of the machine must be operated by authorized professionals, and attention should be paid to local regulations, especially those on protective measures. Power supply parameters: There is a sign with relevant power supply parameters beside the mains switch on the electric control cabinet of the machine. See Figure 2.2.1.

2.2.2 Earth leakage protection and power connection

Warnings The supply voltage must be consistent with the operating voltage on the sign. If the machine is connected to the earth leakage circuit breaker, the full current-sensitive earth leakage circuit breaker with the following attributes must be used: Earth leakage circuit breaker: As per IEC 60755 A2 type B. Full current sensitive type (required to conform to GB19212. 1-2008). Trigger current 300 mA (without personnel protection). Fuse burn-out speed 300 ms. Power connection: (1) Lead the power line into the high-voltage control cabinet through the specified opening hole. (2) Connect yellow/green grounding conductor to grounding copper bar, and N terminal to N terminal. (3) Connect conductors L1, L2, and L3 to terminals L1, L2, and L3 of the main switch, as shown. (4) Tighten the terminals. (5) Recheck if all rotary terminals have been tightened. They might become loose during transportation. Danger: Exposure to dangerous voltage may lead to the most severe trauma and death. The main connection should only be carried out by electrically qualified personnel. Tighten all rotary terminals in the electric control cabinet. The unconnected terminals might cause damage to the main switch and other components. Figure 2.2.2 Locking example. When operating power-driven and hydraulic systems, always turn off the main switch and lock it to prevent the machine from being accidentally reconnected.

2.3.1 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.

2.3.2 Cooling water additives, pressure and flow

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 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.

2.3.3 Cooling system flushing procedures

Precautions: Cooling system washing. Warnings 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. Please connect the valve block intake of cooling water to the industrial water. Connect a proper hose to the valve block circuit of cooling water, and lead it into a matched container. Please slightly turn on the intake. Please flush the cooling system with plenty of water. Please turn off the intake. Please connect the return line to the industrial water pipe. Please turn on the intake. Information: Separately wash the cooling water circuits independent of one another in the same way.

2.5.1 Hydraulic oil naming and classification

Name of hydraulic oil: Please check the name of hydraulic oil from the list below. H = hydraulic oil, V = active ingredients for improving viscosity and/or temperature change characteristics, L = active ingredients for improving anti-corrosion and/or antiaging performance, P = active ingredients for reducing wear and/or improving load capacity, D = active ingredients with cleaning and dispersion properties (having cleaning effect, with staling components and foreign matters remaining suspended) can delay the next maintenance time of the filter element. 46 = dynamic viscosity at 40 , allowing ±10% fluctuation as per DIN standard. ZAF = zinc and ash-free, PAO = polyalphaolefin, synthetic mineral oil, HC = hydrocracking, base oil based on the state-of-art technology and with high viscosity index, EP = extra-high pressure, active ingredient used for highperformance lubricating oil additives with high pressure stability AW = anti-wear agent, active ingredient for improving viscosity and non-skid property, LAV = exhaust characteristic.

2.5.2 Cleanliness class of hydraulic oil

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 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. ISO4406:1999 (International Standardization Organization). The particle size is classified as per 4 mm, and 6 mm and 14 mm. The number of particles obtained by counting will be determined cumulatively and explained according to the ordinal number specified in the ISO4406:1999 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 mm, 15 indicates particles whose size is 4 mm, 12 indicates particles whose size is 4 mm. 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. 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 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 liquid condition monitoring: The hydraulic oil of the cleanliness class above meets the requirements for the fast running hydraulic device with control valve in the injection machine. The effectiveness of the machine can be continuously enhanced by improving the cleanliness class and maintaining the required state of hydraulic oil. At this time, an overall scheme for liquid management is required, mainly including the following aspects: High-performance lubricating oil: Selected lubricants with higher reserve capacity (LAC, AW, EP, wear) should be used (see relevant contents below of this section). Operation/avoidance: Treat the lubricating oil in a way beneficial to the environment and production. Do not replace the lubricating oil (avoid reapplication of oil and mixing). Warehousing should be conducted in the qualified storage tank with integrated filter unit and in the production environment. The cleanliness class in the storage tank, ISO4406:1999 15/12/09. Implementation: The filtering scheme for the machine with circulating filter or bypass filter, based on the 3μm-abs filter. The joint of external filtering equipment is used for cleaning and drainage. Monitoring: Analyze the lubricating oil regularly at an interval of 3 to 6 months (trend analysis). Indicator: viscosity, Acid content, Oxidation, Water content, Pollution. The cleanliness class in the storage tank, ISO4406:1999 - 15/12/09.

2.5.4 Oil analysis and initial fill specifications

Oil analysis: To ensure the failure-free operation of hydraulic system, the hydraulic oil must conform to the requirements described in the section of "Requirements for the 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. Initially filled lubricateng grease and lubricating oil: Select the following hydraulic oil and lubricating oil (grease) of proper types according to the instructions of hydraulic oil manufacturer/hydraulic device component supplier. Table of lubricating oil (grease): Use optional lubricating oil (grease). High-quality lubricating oil (grease) used during initial filling can ensure a longer service life of the machine. 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.

2.5.5 Permitted hydraulic oil and lubricating oil brands

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.

4.1.1 Foundation and heavy object risks

Danger: There is hidden risk caused by excessively low load capacity of the foundation. Excessively low load capacity of the foundation will cause damage to the machine and building. It may endanger personnel safety. Ensure that the foundation load capacity in safe places are consistent with the data in the foundation diagram. (Please refer to the outline drawing and erection plan of the machine recorded in Volume II.) Risk of heavy falling objects: The risk of heavy falling objects always exist during the installation. Never stay under the lifted heavy objects. A lift whose lifting rope or hoisting rope has sufficient bearing capacity is required during the disassembly. Refer to relevant packing data for the size and weight. The layout of lifting rope or hoisting rope. (1) Should ensure that assemblies can be lifted and transported horizontally (without tilt). (2) They should only be installed at specified positions. (3) Their layout should ensure that other parts or assemblies will not be indented or damaged. If there is no appropriate lifter available for the transportation in the workshop, components may be placed on steel rollers (pipes) for transportation. Pay attention to the construction of workshop ground, floor or floor pavement, in case of damage.

4.1.2 Slip, fire hazards and minimum distances

Risk of slip: The engine oil or hydraulic oil on the floor will cause risk of slip. Appropriate filling tools must be used for the filling of lubricating oil and hydraulic oil. Spilled engine oil should be immediately adsorbed and removed according to the environmental requirements. Fire hazards: Lubricating oil or hydraulic oil has the risk of combustion. Avoid open fire and objects with hot surface during operation on the hydraulic system. Appropriate filling tools must be used for the filling of lubricating oil and hydraulic oil. Spilled engine oil should be immediately adsorbed and removed according to the environmental requirements. Figure 4.1.1 Schematic diagram for the minimum distance between the injection position of the machine and the wall. Danger: Keep the gap according to GB12265 (the distance between the injection assembly returned to end as shown above and wall A should be at least 500mm). Danger! The movement of machine components will cause severe dangers between the machine and objects. Set aside at least 1.5m before and after the machine.

4.3.1 Levelness adjustment of small-scale machine

Levelness adjustment of small-scale machine (entire body): To ensure its stability when the machine is running, please make careful and accurate adjustments. Figure 4.3.1 Schematic diagram for the outline size of smallscale machine. Figure 4.3.2 Schematic diagram for the installation of isolator for the small-scale machine tool. (1) Adjustment 0~15mm (2) Machine tool isolator. Adjustment step: (1) Confirm that the machine is at the position where the mold has the minimum thickness. Install the isolator according to the mounting hole of the body. (2) Place horizontally the level instrument between movable platen and rear platen as close to the movable platen as possible, as shown. (3) Adjust the adjustable isolator on the operation side of the machine, so that the level vial can be roughly centered. Then, place horizontally the level instrument at the same position on the reverse operation side. Adjust the adjustable isolator on this side, so that the level vial can be roughly centered. Rotate the level instrument by 90°, and place it respectively on the steel belt or quenched guide rail on the forward and reverse operation side, so that the level vial can be roughly centered. Repeat the steps above several times until the horizontal level is ≤0.16mm/m and the longitudinal level is ≤0.20mm/m.

4.3.2 Levelness adjustment of medium and large-scale machine

Adjustment of levelness of medium and large-scale machine (split body): Figure 4.3.3 Schematic diagram for clamping components of medium and large-scale machine. (1) This is level measuring position (2) Shock--proof pad. Figure 4.3.4 Schematic diagram for the isolator of medium-scale machine tool. (1) Shockproof foot pads for medium and large machines (2) Adjusting screw,hexagon socket M30. Adjustment step: (1) Before installing the machine, clean up the foundation in advance, and then properly place the adjustable isolator according to the dimensions as shown by the foundation installation drawing in Volume II, and lift components stably from the ground by 500mm. Place anchor bolts from the bottom up, with flat washers, spring washers and nuts fastened, and screw down nuts, so that the bolt face is 5-10mm higher than the upper end face of the nut. (2) Place the machine on the isolator. Note to ensure that the anchor bolts of the body align with the preformed holes, and then firmly connect the injection parts to the clamping parts in the method as described in 3.3.1. (3) Confirm that the machine is at the position where the mold has the minimum thickness.

4.3.3 Fine adjustment and anchor bolt curing

(4) Place horizontally the level instrument between movable platen and rear platen as close to the movable platen as possible, as shown. (5) Adjust the adjustable isolator on the operation side of the machine, so that the level vial can be roughly centered. Then, place horizontally the level instrument at the same position on the reverse operation side. Adjust the adjustable isolator on this side, so that the level vial can be roughly centered. Rotate the level instrument by 90°, and place it respectively on the steel belt or quenched guide rail on the forward and reverse operation side, so that the level vial can be roughly centered. Repeat the steps above several times until the horizontal level is ≤0.16mm/m and the longitudinal level is ≤0.20mm/m. (6) After determining the levelness with the level instrument, carry out concrete casting in the preformed holes of the foundation and fix the anchor bolts. (7) After the curing for a period of time, confirm that the cast concrete has been set (the curing period in summer is about ten days, and such period in winter is about fifteen days), and then repeat step 5 for the fine adjustment of the body levelness. Finally, fix the machine firmly by tightening the anchor bolts and nuts after determining the levelness with the level instrument.

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: (1) After machine transportation. (2) If the machine has been adjusted. (3) After the repair and maintenance of injection assemblies. 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. Preconditions: (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. Warnings: Risk of ejection: 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. Measuremet 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.

4.4.2 Adjustment of nozzle center

Adjustment methods for nozzle center alignment on small-sized, medium-sized, and large-sized machines.

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.

6.7.1 Safety instructions for mold installation

Danger: The mold may fall in installation or dismantling. The mold must be reliably hung up with slings under any circumstance during installation, until the tightening of all fixing bolts/the holding-down of the clamping cap/the entry of the hydraulic mold holder into holding-down working state/the normal service of the magnetic die plate. Warnings: A heated mold poses burn risk. Operators working in the mold installation area must wear personal protective equipment (safety shoes, protective clothing, face shield, and safety gloves). Caution: For the sake of machine safety, ensure that mold size is no greater than the die plate size of the machine. Comply with currently valid regulations on accident prevention in mold installation. Only allow trained professionals to install/dismantle the mold. Flush the water/oil channels of the mold not to be used, and store the water/oil flushed out of these channels. Flush the water/oil channels using a clean medium before reinstalling the mold. Prevent the reinstalled mold from bringing dirt into the circuits of the machine. Do not drain the flushed waste water/oil directly into the pipeline network or nature, and transfer them to a professional recycling body for proper disposal.

6.7.2 Preparations before mold installation

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

6.7.3 Steps of mold installation

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

2. 2. Turn on power supply, and set mold opening clearance according to the spatial distance required for mold release after mold opening.

3. 3. Set ejection stroke according to the design parameters of the mold and the distance required by the product, and select necessary ejection function.

4. 4. Start the servo motor, and press the mold adjustment key to enter mold adjustment state.

5. 5. Manually adjust mold thickness to the required value in mold adjustment mode according to the actual thickness.

6. 6. 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.

7. 7. Move the injection blend backwards; Turn off the servo motor.

8. 8. 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). 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.

9. 9. 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.

10. 10. Start the servo motor. Press the mold adjustment key to enter mold adjustment state. Perform mold closing in jog mode, so that the moving die plate gradually comes into contact with the mold until clinging to it.

11. 11. Turn off the servo motor.

12. 12. 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.

13. 13. 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.

14. 14. Start the servo motor. Start with mold opening, and end with mold opening.

15. 15. Close the safety gate, and press the secondary mold adjustment function key to enter automatic mold adjustment state.

16. 16. Switch on and off the safety gate again for automatic mold adjustment, after which the machine is restored to manual mode.

17. 17. Press the mold closing key for mold closing, and turn off the servo motor after mold closing.

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

19. 19. 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

Safety precautions that must be observed during injection moulding operations, including electrical, thermal, and mechanical hazards.

6.8.2 Hydraulic oil temperature

The optimal working temperature of hydraulic oil is 40 55, as a temperature below 40 means excessively high viscosity and a temperature above 55 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), 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

Caution: The operation must be doing under manual model. Note that an excessively high back pressure increases stocking energy consumption, extends stocking time, and reduces machine capacity.

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 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.

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.

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 semiautomatic 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 servo 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.

7.2.1 Daily inspection items

Table 7.2.2 Daily inspection items.

7.2.2 One month inspection project

Table 7.2.3 One month inspection project.

7.2.3 Three months inspection project

Table 7.2.4 Three months inspection project.

7.2.4 Six months inspection project

Table 7.2.5 Six months inspection project.

7.2.5 One year inspection project

Table 7.2.6 One year inspection project.

7.3.1 Examination of the emergency stop switch

When the operation starts and the operators change shifts, the equipment shall not be operated until the action confirmation of the following interlocking and safety devices is completed. 1) Press the "emergency stop" button on the operation side guard board, the button will be locked, and the alarm display of "pressing the emergency button" should appear on the computer screen. 2) When the "emergency stop" button is pressed, "motor start" and "heating" cannot be started. 3) Rotate the "emergency stop" button along the arrow direction (clockwise direction) to reset. 4) Confirm the "emergency stop" button on the no operation guard board.

7.3.2 Examination of the limit switch of the safety door

The safety door is equipped with a limit switch for checking its switch. Please check the action of each safety threshold switch according to the following methods. 1) Open the safety door on the operation side, and the computer screen will display the alarm of "front safety door open". The machine cannot switch the mould and the thimble. 2) Open the safety door on the non-operation side, the computer screen will display the "rear safety door open" alarm, and the motor will be shut down. 3) When the nozzle protection is turned on, the computer screen will display the alarm of "nozzle protection cover open", and the machine cannot perform injection, material storage and table action.

7.3.3 Examination of the limit switch

Limit switches are installed on the back template and pedestal to ensure that the movement travel does not exceed the range. Please check the function of each switch according to the following methods. The limit switch of the equipment is a proximity photoelectric switch, which can trigger the signal when metal objects are sensed within the sensing distance. Caution: Warning to check this content requires two people to cooperate with the inspection. 1) Open the operation side repair door, use the metal rod to adjust the mould into the limit switch induction range, the computer screen should appear "adjust the mould to the end" alarm display, press the [mould forward] button, the machine cannot move. In the same way, the metal rod should be placed in the induction range of the switch, and the alarm display of "adjust the die to the end" should appear on the computer screen. Press the [mould back] button and the machine cannot move. Close the repair door after testing. 2) Open the seat limit switch protection cover, put the metal rod into the terminal limit switch induction range, the computer screen should appear "seat into the final limit" alarm display, press the [carriage forward] button, the machine cannot move. When the metal rod is placed in the range of the terminal limit switch, the alarm display of "the Terminal limits" should appear on the computer screen. Press the [carriage back] button and the machine cannot move. After testing, reinstall the switch protection cover.

7.3.4 Examination of automatic grease supply device

The injection-moulding machine mainly adopts centralized automatic grease supply system. The working condition of the lubrication system will seriously affect the performance and life of the machine.

7.3.5 Inject grease into the linear guide of carriage forward

1) Stop the injection-moulding machine and cut off the power supply of the motor. 2) Use the oil gun to inject grease into the oil nozzle on the sliding foot (front and rear). Squeeze each nozzle about 10 times. 3) Wipe off the spilled grease, and carry out several full stroke bench movements back and forth. Caution: Inject grease into injection bearing block and thrust each 3 month. Please cut off electricity while injecting grease. Please tear down oil plug of its return point while injecting grease. Otherwise, oil seal point might be damaged. Please keep the speed under 1.6ml/s while injecting grease, you cannot put the oil plug back to the oil return point position until oil flows from injecting position.

7.3.6 Inspection of ball screw

1) Stop the injection-moulding machine and cut off the power supply of the motor. 2) Visually check the grease feeding status at the lubrication points of the ball screw, such as injection, mould locking, ejection and ejection. If necessary, please carry out grease feeding operation. 3) Remove the dirt on the screw surface and visually inspect whether there is scratch and wear on the screw surface. 4) New grease shall be applied to the surface of lead screw without grease cover. 5) Start the motor, and conduct low-speed full stroke action on the lead screw, and run back and forth for 3-5 times. Caution: It is forbidden to use chemical cleaning agent when cleaning the dirt on the screw surface, so as to avoid the formation of grease protection film on the screw surface. The grease applied on the lead screw shall be of the same brand.

7.3.7 Cleaning of cooling fan

If the cooling fan of servo motor and distribution box is adhered with dust and other impurities, the cooling effect will be reduced and become the cause of motor and control device failure. In addition, the cooling fan itself has become the cause of failure, so please carry out regular cleaning. Caution: The fan on the servo motor is started and stopped by the computer according to the motor temperature. Only when the motor temperature is higher than the starting temperature (internal setting of 50 degrees), the fan will work.

7.3.8 Mould height adjustment inspection

If the mould is not replaced during the continuous injectionmoulding operation for a long time, it may cause the lack of oil film between the rear nut and the pull rod thread, resulting in the failure of mould thickness mechanism and the failure of mould adjustment. Regular die thickness adjustment checks are required. 1) Start the motor to make the moving template in the open state. 2) Switch to the mould adjustment mode and move forward until reaching the limit position of the die advance. 3) Turn off the motor, remove the dirt on the adjusting gear and rod thread, and brush the grease with a brush. 4) Start the motor to adjust the mould backward, so that the machine completes a full stroke of mould adjustment action.

7.3.9 Check of synchronous wheel

There is a risk of getting involved in injury. When checking the synchronous wheel, the main power supply must be hit to the off position. Synchronous wheel disassembly needs special tools, users do not start to remove the synchronous belt to avoid equipment damage.

7.3.10 Fastening of wiring terminals and plug-ins inside and outside the electrical box

Alert: Danger of electric shock. Check in the distribution box must hit the main power supply to the off position. In addition, in the state of cutting off the main power supply, the power appliance (capacitor, crystal power tube) has the charge of charging in a short time, it is strictly forbidden to touch by hand, wait at least one minute before checking. In the state of cutting off the main power circuit breaker of the injection-moulding machine, fasten the installation screws and wiring terminals of the electrical equipment inside the electrical box and the power supply part. In addition, confirm that electrical equipment and terminals should not cause discoloration due to heat, sparks, etc.

7.3.11 Inspection of uninterruptible power supply batteries

The equipment is equipped with uninterruptible power supply to ensure that the injection-moulding machine can stop running under sudden power failure. Uninterruptible power supply plays an important safety role in the equipment, need to check its function is normal. The inspection method is to cut off the main power circuit breaker of the injection-moulding machine, to see if the injection-moulding machine controller continues to work, and the controller is cut off after 5 seconds of continuous operation, which indicates that this function is effective. If not, need to replace the uninterruptible power supply battery in time.

7.3.12 Bearing base grease supply

Caution: Please be sure to use the specified grease. Grease type see injection-moulding machine oil sign.

1. 1

   1) Remove injection safety cover on operating side

2. 2

   2) Unscrew the return plug on the refueling block

3. 3

   3) Grease the bearing base at a speed not exceeding 1.6 cc/sec until clean grease flows out of the return port

4. 4

   4) Clean grease at return port, reinstall oil plug and safety cover

7.5.1 Structure of cooler

Structure of watercooling 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 hightemperature fluid and achieve cooling purpose. Figure 7.5.1.1 Structure of cooler (large-sized machine, installed externally): (1) Water inlet cover (2) Baffle (3) Heat transfer tube (4) Return cover (5) Tube (6) Install the tripod. Figure 7.5.1.2 Structure of cooler (small-sized machine, installed internally): (1) Water inlet cover (2) Baffle (3) Heat transfer tube (4) Mounting flange (5) Tube.

7.5.2 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 7.5.2.1 Fresh water quality requirements. Cooler data: Cooler model and cooler inlet/outlet thread size, as provided in the table below. Table 7.5.2.1 Cooler model and cooler inlet thread size.

7.5.3 Detection, maintenance, and cleaning of cooler

7.5.3.1 Detection of cooler

Detection of cooler: Refer to the structure of the cooler, and open its end cover for check: 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. Check all sealing washers to see if they are intact. 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. 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.

7.5.3.2 Maintenance of cooler

Common faults and solutions: Table 7.5.3.2.1 Common faults and their handling methods.

7.5.3.3 Cleaning of cooler

Clean the cooler in case of weakened cooling effect. Dismount end covers on both sides (only one side on some machine models), and check for signs of dirt or corrosion. Clean the cooler at least once every half a year. Use a commercially available alkaline cleaner, and clean the main body and the heat transfer tube. Clean an intractable sandwich structure with a weak hydrochloric acid solution, and thoroughly flush the main body and the heat transfer tube. Where there is too much incrustation on the inner side of the heat transfer tube, Please soak it in a cleaner capable of dissolving incrustation, and flush it with clean water and a suitable brush. 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.

7.6.1 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 7.6.1.1). 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 7.6.1.2), 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 7.6.1.3.

7.6.2 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 7.6.2.1.

7.6.3 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.

7.6.4 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.

7.9.1 Hydraulic hose module inspection

Danger: Risk of fatal serious injuries. When the hydraulic hose module is damaged, a tiny liquid column takes shape due to high pressure. The liquid column can cut or penetrate into the skin, causing toxicity. Medical help should be sought immediately in case of injuries due to fluid or grease invasion. It is strictly prohibited to touch the liquid column! It is required to immediately turn off the machine, and repair damaged components. Hydraulic hose module: All the hydraulic hose modules of the injection moulding machine need to be detected each time after 5,000 h of normal running. Such detection must be performed by professionals or professional agencies. Professionals refer to persons who have accumulated adequate knowledge in the field of hydraulic hose module based on specialized training and practical experience, who are familiar with the industrial safety rules, accident prevention policies, and acknowledged technical specifications of the country concerned, and who can judge the safe working state of hydraulic hose modules.

7.9.2 Possible defects in hydraulic hose modules

Possible defects: Described below are some defects which may be caused by the emergency replacement of a hydraulic hose module: Damage to the lining of the outer layer of the hydraulic hose module (dry area spot, notch, or crack). Outer layer embrittlement (cracking hose material). Deformation of the hydraulic hose module in pressure less/pressurized state or under bending. Surface separation, air bubbles, pressure loss point, or breakage point. Poor sealing of the hydraulic hose module. Figure 7.9.1 Hose module diagram: (1) Outer layer (2) Lining. Stripping of the fittings of the hydraulic hose module. Damaged or corroded fittings (declined durability of fittings or hose/fitting connections). Corroded fittings, and declined functions and durability. Figure 7.9.2 Hose marking diagram: (1) Accessories (2) Number.

7.9.3 Cooling water and hot water pipe inspection

Cooling water tube: Similar to the hydraulic hose module, the cooling water pipe of the injection moulding machine must also be regularly checked (at least once every 5,000 h). Hot water pipe: The manufacturer's provisions and relevant safe operation rules should be complied with when using steam or hot water pipes. The check cycle and service life of steam and hot water pipes are very short. Regular detection helps to avoid possible dangers, and possible sealing performance problems which may induce damages. Possible defects: Described below are some major defects which may be caused by the emergency replacement of a water pipe or joint fitting: Damage to outer layer (dry area spot, notch, or crack). Deformation or breakage point of hose module. Poor sealing of hose module. Damage to joint fittings. Warnings: Danger of burn and overflow posed by damaged hoses and fittings. Combustion danger faced by steam or hot water pipes. Recheck of water pipes at least once every 5,000 h.

7.10.1 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.

7.10.2 Mounting and dismounting of the front barrel

Steps of mounting the front barrel: Check fixing bolts (configured according to the machine standards of the company) to see that they are grade 12.9 highquality bolts, and evenly apply high temperature-resistant lubricating grease(such as MoS2)on the thread surface of bolts. 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. 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 7.4 about 10 min later. Figure 7.10.2.1 Front barrel mounting diagram: (1) Bolt (2) Front barrel (3) Screw head (4) Charging barrel. Steps of dismounting the front barrel: 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. Unloosen bolts in diagonal order. Dismount band heaters and temperature detection thermocouples on the front barrel and the nozzle. Wrench. 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. Take off the front barrel.

7.10.3 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.

7.10.3.1 Articles to be prepared for removing screws

Articles to be prepared: 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.

7.10.3.2 Preparations for removing screws

Preparations for removing screws: Heat the barrel to approximately the maximum temperature of the resin used (the temperature can be raised by 50 for the nozzle and the second area to make convenience for removing the fixing screws of the front barrel). Close the blanking port, and empty the barrel. Cut off the power supply of the band heater. Dismount the blanking plate corresponding to the injection unit. Retract screws to leave sufficient removal space. Remove band heaters on the nozzle and the front barrel. 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. Perform suck-back action to disengage screws from the coupling spindle, as illustrated below. Figure 7.10.3.2.1 Diagram of screw-tail removal.

7.10.3.3 Screw removal

Multi-step procedure for removing screws from the injection moulding machine barrel.

7.10.3.3.1 Step 1-2: Preparation and bracket 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 7.10.3.3.1 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 7.10.3.3.2), unloosen the adjusting swivel nuts on the outside of these fixing bolts (② in Figure 7.10.3.3.2), and unscrew left and right adjusting bolts (③ in Figure 7.10.3.3.2); Figure 7.10.3.3.2 Diagram of injection bracket removal. (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 7.10.3.3.3 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 7.10.3.3.4 Diagram of padding the integral movable hanger with wood for integral retraction.

7.10.3.3.2 Step 3-4: Front barrel and nozzle removal

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 7.10.2). Step 4 of screw removal: Removal of the front barrel and the nozzle (refer to the steps in 7.10.2). Figure 7.12.3.3.5 Diagram of removing the front barrel and the nozzle.

7.10.3.3.3 Step 5: Screw extraction

Step 5 of screw removal: removal of screws and screw head unit. Confirm that all the steps in 7.10.3.2 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 7.10.3.1), 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 7.10.3.3.6 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 7.10.3.3.7 Diagram of screw removal. Warnings: 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).

7.10.3.4 Screw head removal

Removal method: Operate the wrench on the screw-tail (keyway) bush (#4 in Figure 7.10.3.4.1). Use a special-purpose wrench to hitch the screw head (#1 in Figure 7.10.3.4.1). Face the screw, and rotate the wrench clockwise to loosen and disengage it. Note in particular that the screw has left-hand thread. Figure 7.10.3.4.1 Diagram of screws and related parts: (1) Screw head (2) Check ring (3) Thrust ring (4) Screw (5) Special-purpose wrench for screw heads.

7.10.3.5 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 7.10.3.4.1). Mount the check ring (#2 in Figure 7.10.3.4.1) and the thrust ring (#3 in Figure 7.10.3.4.1) 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 7.10.3.4.1). Operate the handle on the screw-tail (keyway) bush. Use a special-purpose wrench for screw heads (#5 in Figure 7.10.3.4.1) to hitch the screw head. Face the screw, and rotate the wrench and the handle counterclockwise to tighten it. Figure 7.10.3.4.1 Diagram of screws and wrench.

7.10.3.6 Mounting of screws

Mounting of screws: Mount screws on the machine by steps opposite to the steps for dismounting them in 7.10.3.3.

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

7.10.4.1 Barrel dismounting

Multi-step procedure for dismounting the barrel from the injection moulding machine.

7.10.4.1.1 Steps 1-3: Preparation and bracket removal

Step 1 of barrel dismounting: Warnings: 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 7.10.4.1.1 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 7.10.4.1.2 Diagram of dismounting barrel-related auxiliary devices. Step 3 of barrel dismounting: (1) Remove the two fixing bolts close to the thrust block direction (#1 in Figure 7.10.4.1.3), unloosen the adjusting swivel nuts on the outside of these fixing bolts (#2 in Figure 7.10.4.1.3), and unscrew left and right adjusting bolts (#3 in Figure 7.12.4.1.3), as illustrated below; Figure 7.10.4.1.3 Diagram of injection bracket removal. (2) Dismount the piston rod hanger screws of the integral movable cylinder on the front die plate; Figure 7.10.4.1.4 Diagram of dismounting the fixing bolts of the integral movable hanger. (3) Perform integral advance action to retract the integral movable cylinder. (4) Place wood between the front die plate and the piston rod hanger of the integral movable cylinder. Figure 7.10.4.1.5 Diagram of integral sled retraction. (5) Perform integral retraction action, retract the injection blend to a suitable position, and hang the slings on the barrel.

7.10.4.1.2 Steps 4-5: Hoisting and lock nut removal

Step 4 of barrel dismounting: 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 7.10.3.2 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 7.10.4.1.7 Diagram of removing the lock nuts of the barrel.

7.10.4.1.3 Step 6: Barrel extraction

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 7.10.4.1.8 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 7.10.4.1.9 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.

7.10.4.2 Barrel mounting

Barrel mounting: Mount the barrel by steps opposite to the steps for dismounting it in 7.10.4.1.

7.10.5 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 7.10.1~7.10.4. 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).

7.10.5.1 Screw cleaning

Clean screws: (1) Wipe clean screw body with waste cotton, so as to remove most resinous deposits. (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) 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) After screws cool down, use a non-inflammable solution to wipe clean all the oils. Figure 7.10.5.1.1 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.

7.10.5.2 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.

7.10.5.3 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 , 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.

7.10.5.4 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 7.10.5.4.1 Diagram of the barrel module: (1) Nozzle (2) Front barrel (3) Charging barrel (4) Lock nuts of the barrel.

7.10.6 Mounting of thermocouple

7.10.6.1 Replace the thermocouple on the barrel

Dismount the thermos-couple: Turn off the master switch on the machine first for the sake of safety. Take off the guard of the blanking barrel module. Please screw out the screwed connector bush on the thermocouple, and take it out of the hole. Please unloosen the corresponding thermocouple terminal in the heater terminal box, and take out the wire. Mounting of thermocouple: Please verify the model, and unpack the new thermocouple after confirmation. Please thoroughly clean the thermocouple hole (inaccurate measurement!). 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. Please route the wire along the heating path, connect the thermocouple wire to the terminal in the terminal box, and tighten it. 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.

7.10.6.2 Replace the thermocouple on the nozzle

Dismount the thermos-couple: Please turn off the master switch on the machine first for the sake of safety. Please loosen the thermocouple on the nozzle, and take it out. Please open the heater terminal box, loosen the corresponding terminal, and take out the thermocouple wire. Mounting of thermoscouple: Please verify the model, and unpack the new thermocouple after confirmation. Please thoroughly clean the thermocouple hole (inaccurate measurement!). Please insert the thermocouple into the nozzle, and tighten it. 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 7.10.6.2.1 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.

7.10.7 Replace band heaters

7.10.7.1 Replace band heaters on the barrel

Dismount band heaters: Cut off the power supply of the machine. Remove the screws on the barrel module (upper and lower) guard. Take off the guard of the blanking barrel module. Screw out the thread socket on the thermocouple. Pull the thermocouple out of the hole. Loosen the power wire on the heater terminal. Loosen the heater connecting wire on the terminal strip. Unloosen the fixing screws of band heaters. Move out band heaters towards the front end of the barrel (nozzle direction). 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. Figure 7.10.7.1 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.

7.10.7.2 Replacement of the nozzle band heater

Replace the nozzle band heater: Please turn off the master switch on the machine for the sake of safety. Dismantle the power wire of the nozzle band heater. Unfasten the fixing screws of the nozzle band heater. Dismount the nozzle band heater. Mount a new nozzle band heater. Set the screws of the nozzle band heater on the sides. Tighten them. Figure 7.10.7.2 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.

7.11.1 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 7.11.1 Diagram of the gliding feet of the moving die plate of a small-sized machine: (1) Adjustment column (2) Lock nut.

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 caused by material feed clogging, nozzle freezing, and overheating during interrupted operation. All faults must be cleared by trained professionals.

8.3.2 Poor quality of plastic products and solutions

Causes and solutions for poor quality plastic products. After changing one factor, the results of such change should be examined before moving on to another factor.

9.2.1 Simple clamping force calculation

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 clamping force calculation and simulation

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 2inch in width, 9inch in length, and 0.05inch 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.