Wittmann Battenfeld - Smart - Power - Operating - Instructions

O P E R AT I N G I N S T R U C T I O N S
PRODUCT LINE SmartPower B6
00 0115
SM1GBV
Read before using the injection moulding ma-

chine and keep nearby for reference.
TECHNOLOGY working for you.
Wittmann Battenfeld GmbH

Wr.Neustädter Straße 81 • 2542 Kottingbrunn • Österreich
Tel. +43 (0) 2252 404-0 • Fax +43 (0) 2252 404-6102
info@wittmann-group.com
www.wittmann-group.com/
DIN EN ISO 9001
Subject to technical changes without prior notice.

We shall not accept any liability for damage caused by printing errors.
Operating Instructions
Production line SmartPower
Machine model xxx / xxxx
Control system type UNILOG B6x
Machine number 135xxx-100
Year of manufacture 2014
Number of instruction manual SM1GBV00_0115
Date of issue 14.01.2015

1.................................................................................................................Preface
1.1.......................................................................................................................................................... Introduction
1.2..............................................................................................................................................Area of Applicability
1.3........................................................................................................................................ Explanation of symbols
1.4..............................................................................................................................................................Copyright
1.5...................................................................................................................................... Certificate of Conformity
1.6.......................................................................................................................................Commissioning protocol
2...................................................................................................................Safety
2.1................................................................................................................................................ Safety regulations

2.1.1.......................................................................................................................................... General information
2.1.2.........................................................................................................................................................Installation
2.1.3..............................................................................................................................Operation and maintenance
2.1.4............................................................................................................. Safety instructions affecting personnel
2.1.5...................................................................................................... Safety regulations Hydraulics / pneumatics
2.1.6.......................................................................................Safety regulations for the Modular Airmould® System
2.1.7.....................................................................................................Safety regulations for moulding compounds
2.1.8..........................................................................................................................Safety regulations for electrics
2.1.9................................................................................ Safety regulations for changing nozzle, screw and barrel
2.1.10..................................................................................................................... Safety instructions Environment
2.2.................................................................................................................................... Table for risk assessment
3...................................................................................................... Technical data
3.1............................................................................................................................................. General information

3.2............................................................................................................................................ Hydraulic equipment
3.3.............................................................................................................................................Electrical equipment
3.4....................................................................................................................................................... Water system
3.5.........................................................................................................................................................Pump output
3.6.........................................................................................................................................................Injection unit
.................................................................................................................................................... SmartPower 25/35
.................................................................................................................................................... SmartPower 50/60
.................................................................................................................................................... SmartPower 80/90
.................................................................................................................................................SmartPower 110/120
3.7....................................................................................................................................................... Clamping unit
.................................................................................................................................................. SmartPower 25 / 35
.................................................................................................................................................... SmartPower 50/60
.................................................................................................................................................. SmartPower 80 / 90
.................................................................................................................................................SmartPower 110/120
3.8................................................................................................................................................ Mould dimensions
3.9........................................................................................................................Conversion table for shot weights
3.10...........................................................................................................................Weights of screws and barrels
3.11 .....................................................................................................................................Torque settings for bolts
3.12.................................................................... Torque settings for the fastening screws of the screw barrel head
3.13................................................................................................................................................................ Layout
SM1GBI2A
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Index - 1
4......................................................................................... Transport - Installation

4.2............................................................................................................................................. Unpacking / storage
4.3.............................................................................................................................................................Unloading
4.4.......................................................................................................................................Space requirement plan
4.5.................................................................................................................................... Transporting the machine
4.6........................................................................................................................................... Erecting the machine
4.7...........................................................................................................................................Transportation device
4.8............................................................................................................................ Removing preservative agents
4.9.......................................................................................................................................... Levelling the machine
4.10................................................................................................................................................Hydraulic system
4.10.1...............................................................................................................................................................Filling
................................................................................................................................................ SmartPower 25 - 120
4.10.2............................................................................................................ Commissioning of the hydraulic pump
4.10.3...................................................................................................................................................... Deaeration
4.10.4.............................................................................................................................................. Pressure vessel
4.10.5........................................................................................................................................Bypass filtration unit
4.10.6......................................................................................................................................... Core puller (option)
4.11 ..................................................................................................................................................... Water system
4.11.1 ................................................................................................................................................... Water quality
4.11.2 ................................................................................................................................Cooling water connection
4.11.3 ........................................................................................................................... Cooling water flow governor
4.11.4 ....................................................................................................................................................... Oil cooling
4.11.5 ................................................................................................................................. Temperature control unit
4.12..............................................................................................................................................Pneumatic system
4.12.1................................................................................................................................................. Air supply unit
4.13...........................................................................................................................................Electrical equipment
5................................................................................................... Mould mounting
5.1 ......................................................................................................................................................... Preparation

5.2................................................................................................................................................... Mould mounting
5.3.................................................................................................................. Quick-action mould mounting system
5.4................................................................................................... Magnetic quick-action mould mounting system
5.5............................................................................................................................................................. Interfaces
5.6................................................................................................................................ Checking the safety devices
5.7 ................................................................................................................................... Test run and interlock test
6..........................................................................................Structure and function
6.1....................................................................................................................................................... Clamping unit

6.1.1.........................................................................................................................................Technical description
6.1.2............................................................................................................................................ Mechanical scotch
6.2.........................................................................................................................................................Injection unit
6.2.1.........................................................................................................................................Technical description
6.2.2....................................................................................................................................................... Screw drive
6.2.3...............................................................................................................................Adjusting the nozzle centre
6.2.4.......................................................................................................Basic requirement for changing the nozzle
6.2.4.1............................................................................................................................... Changing "open” nozzles
SM1GBI2A
Index - 2 0115TW
6.2.4.2............................................................................................................................................ Nozzle changing
6.2.4.2.1.......................................... Replacing the "Herzog" needle shut-off nozzle of type SHP, spring-controlled
6.2.4.2.2....................................................................................... Changing the "Fuchslocher” needle valve nozzle
6.2.4.2.3.............................. Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle,
................................................................................................................... type HP, with integrated control cylinder
6.2.4.2.4............................................................ Replacing the pneumatically triggered "Herzog” bolt valve nozzle,
................................................................................................................... type HP, with integrated control cylinder
6.2.4.2.5............... Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP
6.2.4.2.6....................... Replacing the pneumatically or hydraulically triggered "Fuchslocher" needle valve nozzle
6.2.4.2.7........................................................ ENG pneumatic needle valve nozzle with integrated control cylinder
6.2.5................................................................................................................ Dismantling the screw barrel / screw
6.2.5.1 ........................................................................................................... Dismantling the screw up to size 750
6.2.5.2 ................................................................................................. Dismantling the screw barrel up to size 750
6.2.5.3 ................................................................................ Retooling for a different screw diameter up to size 750
6.2.5.4.............................................................................................................................. Dismantling the screw tip
6.2.6.............................................................................................................. Cleaning the barrel, material changes
6.2.7................................................................................................................. Purging out with virgin polyethylene
6.2.8........................................................................................................... Purging out with a barrel purging agent.
6.2.9................................................................................................................................. Cleaning the screw barrel
6.2.10........................................................................................................................................................... Storage
6.3............................................................................................................................................................ Hydraulics
6.3.2..........................................................................................................................................................Pump unit
6.3.3................................................................................................................................................... Hydraulic tank
6.3.4....................................................................................................................................................Pressure filter
6.3.5...........................................................................................................................................................Oil cooler
6.3.6........................................................................................................................................... Control and display
6.3.7................................................................................................................................................ Pressure setting
6.3.8.................................................................................................................................................... Speed setting
6.3.9.................................................................................................................................... Hydraulic oil preheating
6.3.10....................................................................................................................................... Hydraulic core puller
6.4.......................................................................................................................................................... Pneumatics
6.4.1....................................................................................................................................... Pneumatic core puller
6.4.2................................................................................................................................................... Air supply unit
6.5...............................................................................................................................................................Airmould
6.6............................................................................................................................................................... Electrics
6.6.1..................................................................................................................................................... Electric drive
6.6.1.1........................................................................................................................Speed-controlled servo motor
6.6.2...................................................................................................................................................Switch cabinet
6.6.2.1................................................................................................................Switch cabinet layout Main cabinet
6.6.2.2..................................................................................................................Switch cabinet layout Base frame
6.6.2.2........................................................................................................................Switch cabinet layout Heating
6.7.............................................................................................................................................. UNILOG B6 control
6.7.2.................................................................................................................................................. Operator panel
6.7.3................................................................................................................................. Explanation of the picture
6.7.4................................................................................................................................................Saving / Printing
6.7.5..........................................................................................................................................Control components
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Index - 3
7............................................................................................................. Operation

7.2....................................................................................................................................................... Initial start-up
7.3 ............................................................................................... Starting the machine after EMERGENCY STOP
7.4........................................................................................................................... Checking the nitrogen pressure
7.5...................................................................................................................................... Test run without material
7.6....................................................................................................................................Filling the material hopper
7.7........................................................................................................................................... Test run with material
7.8............................................................................................................................................................. Operation
7.9 .................................................................................................................................Shutting down the machine
7.10 .......................................................................................................................................... Extended shutdown
7.11 .........................................................................................................................................Shut down procedure
7.11.1 .................................................................................................................................... Dismantling the mould
7.11.2 ............................................................................................................... Further measures for shutting down
7.11.3 ....................................................................................................................... Emptying the hydraulic system
7.11.4 ................................................................................................................. Emptying the cooling water supply
7.11.5 .......................................................................................................... Evacuating the compressed air system
7.11.6 .............................................................................................................................................. Other measures
7.11.7 ...................................................................................................................Disconnecting the electric system
7.12..............................................................................................................Measures after an extended shutdown
7.13...................................................................................................................... Changing the place of installation
7.14............................................................................................................................................................. Disposal
8........................................................................................................ Maintenance
8.1...................................................................................................................................................... Miscellaneous
8.2...................................................................................................... Transport, storage and disposal of lubricants
8.3................................................................................................ Disposal of electrical and electronic components
8.4........................................................................................................................... Hydraulic oil and lubricant table
8.5............................................................................................................................................... Maintenance chart
8.6..................................................................................................................................................Hydraulic system
8.6.1.........................................................................................................................................................Oil change
8.6.2........................................................................................................................................................ Deaeration
8.6.3........................................................................................................................................ Checking the oil level
8.6.4................................................................................................................................... Oil change Axial bearing
8.6.5................................................................................................................................................... Hydraulic filter
8.6.6............................................................................................................................... Changing the filter element
8.6.7...................................................................................................................................................... Venting filter
8.6.8................................................................................................................................................................ Leaks
8.6.9 ..........................................................................................................................................................Oil cooler
8.7................................................................................................................................................... Pressure vessel
8.7.1........................................................................................................................ Checking the nitrogen pressure
8.7.2................................................................................Replenishing, reducing and testing the nitrogen pressure
8.7.3 ......................................................................................................................Checking the hydraulic pressure
8.8..................................................................................................................................................Hose assemblies
8.8.1........................................................................................................................................................ Service life
8.8.2..............................................................................................................................................Inspection criteria
8.9.......................................................................................................................................... Hydraulic accessories
8.10......................................................................................................................................................... Lubrication
8.10.1...............................................................................................................................Manual grease lubrication
8.10.2..........................................................................................................................................Three phase motor
8.10.3..................................................................................................................................................... Screw drive
8.10.4........................................................................................................................................Corrosion protection
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Index - 4 0115TW
8.11 ..................................................................................................................................................... Water system
8.11.1 .................................................................................................................................................. Water quality
8.11.2 ..........................................................................................................................Closed cooling circuit system
8.11.3 ................................................................................................................................ Hydraulic oil temperature
8.11.4 .........................................................................................................................................................Oil cooler
8.11.5 ........................................................................................................................... Cooling water flow governor
8.12...........................................................................................................................................Electrical equipment
8.12.1....................................................................................................................................................... Filter mats
8.12.2...................................................................................................................................................Buffer battery
8.13..............................................................................................................................................Pneumatic system
8.13.1............................................................................................................................... UNIFEED material feeder
8.13.2................................................................................................................................................. Air supply unit
8.13.3................................................................................................................................................. Filter cartridge
8.13.4.......................................................................................................................................... Mechanical scotch
9......................................................................................................Spares / Plans
10........................................................................................... Special descriptions
.................................................................................................. Customer Service
SM1GBI2A
0115TW
Index - 5
SM1GBI2A
Index - 6 0115TW
1 Preface
1.1 Introduction
The operating manual contains information which is deemed to support the user in his work and
information which must be adhered to in order to guarantee a safe handling.
The complete operating manual should be held close to the machine and be available to
operating and maintenance staff at all times.
There are facilities for the training of your operating staff in your works or at our factory. For
further information, contact the Training Department.
Should you still encounter difficulties, please contact our Customer Service Department or our
Local Technician or Agent (addresses are given in chapter "Customer Service") who will be
pleased to help.
This Operating Manual is valid only for the machine specified on the front cover.
The presentation and content of this manual are subject to technical alteration, as required by
continuous improvements of the machine and / or its plant components.
Liability / Warranty
Wittmann Battenfeld GmbH assumes no liability for property damage and human injury and/or
environmental damage resulting from partial or full non-compliance with the operating manual.
The warranty becomes invalid if unauthorised persons intervene in the equipment.
In the case of personal injury, property damage or damage to the environment, claims by reason
of liability or warranty shall be excluded if the damage can be attributed to at least one of the
following causes:
• If the damage and/or failure can be traced back to the usage of spare parts other than
original spare parts.
• Incorrect operation, insufficient maintenance or insufficient repair of the components.
• Operation of the components with incorrectly attached, defective or non-functional safety
and protective devices.
• Non-compliance with the operating manual for operation, maintenance and repair.
• Changes made to the components without the express approval of Wittmann Battenfeld
GmbH. The attachment or removal of components is particularly prohibited.
• Damage due to foreign bodies or force majeure.
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Please observe the operating manual
Knowledge of the contents of the technical documentation for the components is a precondition
for protecting the employees from danger, preventing errors and for operating the components in a
flawless and safe manner.
• Everyone entrusted with the transport, assembly, initial start-up, operation, maintenance or
repair of the components must be knowledgeable of the operating manual. We recommend
that the operating company require its operating personnel to confirm in writing that they are
familiar with the contents of the operating manual.
• All requirements and instructions in the operating manual must be complied with.
• All applicable national regulations, regulations for accident prevention and environmental
protection and the confirmed technical requirements for safe and proper work must be
complied with.
1.2 Area of Applicability

Machines of this range have been designed as standard for the processing of thermoplastics and,
when using the respective injection units, optionally for processing rigid PVC, thermoset plastics,
elastomers and LIM (Liquid Injection Moulding - process for the injection moulding of liquid two part
silicone rubbers).
Any other use is regarded as improper. The manufacturer accepts no responsibility for any resulting
damage - the risk is borne entirely by the operating company.
ATTENTION
For test purposes, the injection unit was operated with the following material:
Polystyrene STYROLUTION PS 454N (HIPS) processing temperature 180°-260 °C/356°-500 °F
If required, rinse screw barrel with a suitable cleaning material.
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1.3 Explanation of symbols
The Warning symbol is to be found with all work safety instructions in this operating manual
where there is a hazard to the health and safety of persons. Follow these instructions and act in
these cases with extreme care. Pass on all work safety instructions to other users. In addition to
the instructions given in this operating manual the general health and safety regulations must be
observed.
Warning and prohibition symbols may be present on the machine. They warn of particular
dangers of death or injury to operating and maintenance personnel.
The "Hot surface" sign indicates areas where there is a burning hazard. The operating and
maintenance personnel must be protected by appropriate personal protective equipment.
Areas indicated by the "Pinch hazard" sign warn of possible pinching or crushing hazards.
Surfaces marked with the "No step" symbol must not be stood on!
ATTENTION
Caution marks those sections with these operating manual where there are instructions or
regulations which must be observed and/or that the correct sequence of work should be
followed, and / or that care must be taken to avoid damage to the machine and associated
equipment.
The High voltage symbol indicates in the manual those places where personnel can come
into contact with electrical equipment and materials. Care must be taken to ensure that the
applicable local electrical safety regulations are followed.
The mandatory symbols, "Use face protection" and "Wear safety gloves", are to be found at the
mould with mould nozzles of the machine. When the person having access to the mould area
completely enters the machine (according to EN 201), the mandatory symbol "Wear personal
protective equipment" is additionally to be found at the mould.
They warn of particular dangers of death or injury to operating and maintenance personnel. The
user must be protected by appropriate personal protective equipment.
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The symbol for environmental hazard draws attention to environmental hazards, for instance
in disposal of all sorts of materials. When carrying out repair and maintenance work the locally
applicable laws and decrees have to be complied with.
1.4 Copyright
The copyright of this operating manual remains with Battenfeld GmbH. This operating manual is
intended for assembly, operating and supervisory staff. It contains instructions and diagrams of
a technical nature which may not be reproduced entirely or in part, distributed or used without
authorisation for the purposes of competition or conveyed to third parties.
1.5 Certificate of Conformity

The Certificate of Conformity is included at the end of this Section.
1.6 Commissioning protocol

(For internal use only)
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2 Safety
2.1 Safety regulations

2.1.1 General information
Numerous safety devices on the machine contribute to safety and accident prevention. The
proprietor is responsible for the efficient operation of the safety devices.
The machine has been designed and built to the currently applicable safety regulations in
European Standard EN 201 and is safe to operate. Hazards may still arise from this machine if it
is operated by untrained personnel or is used improperly or for an unsuitable purpose.
For safety reasons the control software may not be modified. Any unauthorised modification to
the software will invalidate possible claims of guarantee / warranty.
The regulations on environmental hazards, safety and the prevention of accidents as well as the
internal procedures are always applicable to the running of the machine.
Unless otherwise contractually agreed upon with the manufacturer, the guarding has been
designed according to safety regulations (EN 201) the for an operation of the machine at ground
level.
If the machine, without knowledge of the manufacturer, is installed in a pit or surrounded with a
pedestal, the proprietor is obliged to adhere to the safety regulations according to the European
Standard EN 201, and especially to EN ISO 13857.
Unauthorised modifications and alterations which affect the safety of the machine are not
allowed.
Modifications and alterations which affect the safety of the machine as well as all work relating
to maintenance are to be documented in an inspection record which is to be stored for at least
ten years.
Proper use of the machine includes observation of the instructions laid down by the
manufacturer for assembly, dismantling, commissioning, operation and maintenance.
Responsibilites and procedures for all work involving installation, dismantling, modification and
maintenance of the machine are to be recorded in a procedure.
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The machine is designed and built to the currently valid standard EN ISO 12100 so that the
noise hazard during proper use and with optimum settings is reduced to the lowest practicable
level.
Before operating the machine with a robot, the safety regulations in the "Robot" operating
manual must be followed without fail.
Before operating the machine with integrated peripheral equipment (e.g. material feeder)
the safety regulations in the appropriate Peripheral Equipment Operating Manual(s) must be
followed without fail.
Connection and installation of peripheral equipment may only be carried out by authorised
skilled technician.
The proprietor has to make sure and verify that the operator is aware of the safety instructions
and potential harzards and follows the operating manual at regular intervals.
The installation of a mould-lifting crane from Wittmann Battenfeld GmbH may only be carried
out by an authorised skilled technician. The crane may only be used for installing and removing
moulds. It is forbidden to linger under the suspended load. The Safe Working Load is shown on
the crane's specification plate.
Even if the machine is only subject to slight modifications in terms of position it should be
disconnected from any power supply. Reconnect all power supplies according to the operating
manual before restarting the machine.
If the machine is disposed of to a third party or firm, these operating instructions must be
handed over with it. If is recommended to have written confirmation of this.
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2.1.2 Installation
For installation, dismantling, modification, adaptation, and maintenance, work parts,
components or the entire machine have to be secured and carefully attached to the lifting gear
so as to prevent any dangers from arising. Only use appropriate lifting gear in proper working
order with sufficient carrying force. Personnel or other persons must by no means stand or work
under suspended loads.
Loads may only be fastened, secured and transported by experienced, authorised and trained
personnel.
The machine may only be lifted using the lifting points described in Chapter "Transport -
Installation".
After electrical installation or maintenance all the applicable safety measures (e.g protective-
conductor system, voltage test, insulation test) must be tested according to the European
standard EN60204-chpt20.
Hazards may arise from this machine during setting if the setting is carried out by untrained
personnel improperly or for an unsuitable purpose.
Therefore, all setting work may be carried out by a tool setter only.
Tool setters are persons who due to specialised training and experience have sufficient
knowledge of material, moulds and the control of the machine and who are familiar with the
relevant safety regulations, regulations for the prevention of accidents, directives and generally
approved rules in technology, e.g. DIN standards.
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2.1.3 Operation and maintenance
All work is in principal to be carried out with the machine being idle. The appropriate isolation
procedures must be followed.
Before starting work on the machine its drive and periphery equipment must be secured against
accidental reconnection, e.g. using a padlock on the main switch.
Before reconnecting the machine the safety devices must always be checked for their proper
function and to be documented by the proprietor.
Before putting into operation after repair it must be verified that all the safety devices are in
place according to regulations.
Safety devices may only be removed with the machine switched off and secured against
accidental reconnection.
If the ejector or core pullers are operated with the safety door open, it must be ensured that
there are no pinching or crushing points on the mould.
Spare parts must meet or exceed the technical specification laid down by the manufacturer.
The operator is responsible for ensuring that the electrical components, motors etc. do not come
into contact with any liquid.
Carefully clean the environment, especially connections and screw connections before servicing
the plant.
Cleaning materials are classed as flammable liquids, hazardous to health. The manufacturers'
instructions are to be followed without fail. Do not use aggressive cleaning agents. Use non-
fibrous cleaning cloths.
When using oils, greases or other chemical substances, follow the safety regulations applicable
to this product.
The proprietor is responsible for secure and proper waste disposal of process material.
Screw connections which have become loose during operating and maintenance work must
always be tightened as specified on the table. Check pipework for leaks, loosened screw
connections, chafe marks, and damage. Remedy detected defects immediately.
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2.1.4 Safety instructions affecting personnel
All persons involved with the machine on the proprietor’s premises, whether for installation,
dismantling, commissioning, operation, maintenance (inspection, service and repair) must first
read and understand the appropriate operating instructions, especially chapter "Safety". The
proprietor is advised to have this confirmed in writing.
The machine may only be operated, maintained and repaired by authorised, trained personnel.
Personnel must have undergone special instruction about possible hazards.
Personnel to be trained, instructed or which has not yet finished the professional training may
only work at the machine if supervised by authorised, trained and instructed staff.
The operators must wear their hair tied back, close-fitting clothes and must not wear any jewels
including rings. There is a danger of injury, e.g. when getting caught.
Responsibilities for installation, dismantling, commissioning, operation, and maintenance must
be clearly defined and adhered to so that no grey areas arise on the subject of responsibilities
for safety.
For all work involving assembly, dismantling, modifications and maintenance, the machine is to
be switched off at the mains switch and must be secured against accidental switching on. (e.g.
by inserting a padlock into the main switch).
All energy supply lines to the machines (e.g. compressed air, pressurised fluids, ...) must be
switched off.
When undertaking work involving installation, dismantling, modification, operation and
maintenance, no flammable liquid may be allowed to come into contact with components whose
high temperatures could cause a fire and explosion risk.
Let the following components cool down to a safe temperature before carry out any work
involving installation, dismantling, modification and maintenance:
• Heating elements and their guardings.
• Temperature control units, their fittings, flow and return lines and their mounting elements.
• The outside cooling of the screw barrel (option) and / or the barrel throat zone (option),
operated with water or heat transfer oil, including all fittings, flow and return lines and
mounting elements.
• The internal cooling of the screw (option), operated with water or heat transfer oil,
including all fittings, flow and return lines and mounting elements.
The operator must protect him / herself from burning hazards from the heating elements,
temperatur control units and their covers, fittings, flow and return lines and their mounting
elements, and the housings of electrical motors by wearing appropriate PPE.
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The operator has a duty always to use the machine with closed safety gates and guards.
No working method which compromises safety of the machine should be employed.
The operator has a duty to ensure that no unauthorised person works on the machine.
The operator and other personnel may only stand in front of the machine on the operator’s side
during operation.
It is forbidden to stand on the machine or to reach into the injection unit during operation.
The shut down procedures given in the operating manual are always to be followed for all work
on the machine.
The operator is obliged to report at once any alteration in the machine which affects safety.
If necessary, the machine should be switched off at once by operating the emergency stop
devices and the main switch.
The operator has a duty always to operate the machine in a fault free condition.
Cleanliness and tidiness of the machine are to be ensured by appropriate instruction and
monitoring on the part of the proprietors.
The operator is obliged to observe all safety regulations and danger signs at the machine.
These signs must be complete and fully legible.
If components of the machine are located higher than the average body height, climbing aids
and working platforms which meet the legal safety requirements must be used for installation,
dismantling, modification, operation, and maintenance. Do not use components of the machine
as climbing aid. When working at greater heights, proper equipment for proctection against
falling down must be worn.
The operator has a duty to ensure that no foreign bodies enter the material hopper, stuffing
device, or screw opening.
The operator must without fail ensure proper assembly of the nozzle to prevent risk of its flying
out.
When using mould nozzles (Hot runner nozzle, Mouldmaster nozzles) the operator must ensure
that there are no pinching or crushing points.
The proprietor is obliged to attach corresponding safety labels to moulds (not included in the
scope of Wittmann Battenfeld GmbH of delivery) which are equipped with mould nozzles. These
safety labels must instruct the operator to use the appropriate personal protective equipment for
all work involving installation, dismantling, modifications and maintenance of mould nozzles (Hot
runner nozzle, Mouldmaster nozzles).
When undertaking work involving installation, dismantling, modification, and maintenance of
mould nozzles (Hot runner nozzles, Mouldmaster nozzles), the operator is obliged to wear
appropriate personal protective equipment (protection for hands and face, etc.) (EN 407, EN
420, EN ISO 13732, EN 168).
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Looking directly into the nozzle area itself is not allowed. Use appropriate aids (e.g. a suitable
mirror).
In any work involving operation, installation, dismantling, modification and maintenance, the
following potential pinching or crushing hazards may arise:
• Between the safety door and safety door frame on closing the clamping unit's safety
door(s).
• Between the purge guard and the nozzle platen on closing the purge guard.
• With power-operated shut-off nozzles from the movement of their closing mechanism.
• Between the nozzle and the nozzle platen when moving the injection unit forward with the
purge guard open.
• In the area of the screw shaft and thrust bearing (axial bearing) when coupling the screw.
• Around the material outlet when swinging the material hopper in and out or sliding it
backward and forwards.
Machine with pedestal:
• When opening and closing the power-operated safety gate in the area of the safety gate
drive.
Machines with extended tiebars (with toggle only):
• When setting the mounting height of the mould between guarding and clamping cylinder.
There is a crushing and / or shearing and / or impact hazard in the space for part ejection from:
• Moving parts of the mould area which can be reached through the space for part ejection.
• Falling mouldings.
There is a cutting and shearing hazard at the edge of the filling opening of the hopper when
filling in the melt.
In the area of the Roto feeder head, for the internal cooling of the screw (option), there is a
hazard of crushing and / or shearing between the rotating and fixed parts.
For magnetic quick-action mould mounting systems (option), the following hazards in the
clamping unit area arise from:
• Magnetic fields, which, when in immediate proximity, may influence sensitive devices
such as cardiac pacemakers, hearing aids, disks, etc.
• The power of the magnetic modules which can uncontrollably magnetise objects (e.g.
spanners).
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Chapter 2 - 7
0414MC
2.1.5 Safety regulations Hydraulics / pneumatics
The machine is designed and built to the currently applicable safety requirements of European
Standard EN 4413+ EN 4414 and is safe in operation. Hazards can, however, arise from the
hydraulic system of this machine if it is improperly used by untrained personnel or is used
for purposes for which it is not designed. For this reasons all work involving installation,
dismantling, modifications and maintenance may only be carried out by a skilled hydraulic and /
or pneumatic technician.
Hydraulic technicians are persons who due to specialised training and experience have
sufficient knowledge in the field of oil hydraulics and who are familiar with the relevant safety
regulations, regulations for the prevention of accidents, directives and generally approved rules
in technology, e.g. DIN standards.
Before opening hydraulic and / or pneumatic components and hoses, the hydraulic or pneumatic
systems have to be relieved from pressure as described in this operating manual.
Compressed air piping for the pneumatic system and water pipework for the cooling of the
hydraulic unit have to be expertly installed and laid. Fittings, length and cross section have to
meet the requirements.
Hydraulic fluids (oils) escaping at high pressure can penetrate the skin and cause severe injury.
A physician must be consulted at once as there is also a risk of infection.
All pipework, hoses and screw connections should be checked for leaks and damage visible
from outside at regular intervals. Remedy damage immediately. Hydraulic oil escaping at high
pressure can cause severe injuries and fires.
Hydraulic hoses and hose assemblies have to be replaced at the intervals given in the
"Maintenance" chapter, even if there are no defects to be detected which affect safety.
Hydraulic hoses and hose assemblies must be protected from damaging external influences.
The safety regulations for hydraulic hoses and hose assemblies to DIN 20066 and EN 201 are
to be particularly carefully observed.
Only hose assemblies with fittings that were either supplied or specified by Wittmann Battenfeld
GmbH should be implemented.
All work involving installation,dismantling, modifications and maintenance of pressure vessels
may only be carried out by personnel trained in this field.
EWAGB0BB
Work (repair, connection of a pressure gauge) on a machine with pressure vessels must not
be carried out until the hydraulic pressure has been released; i.e. the pressure in the pressure
vessels must have decayed completely. No welding or machining may be undertaken.
The pressure vessels must be tested at their place of use by the technical standards
organisation responsible in the proprietor's region before being put into operation.
Pressure vessels may only be filled with nitrogen "N2". The use of other gases causes explosion
hazards.
Keep the test certificates for the pressure vessels and safety valves in a safe place.
The proprietor is responsible for the proper condition, operation and monitoring of pressure
vessels (e.g. regular testing). The relevant pressure vessel regulations can be purchased from
the appropriate technical publishers. Addresses can be get from the local technical standards
organisations.
When disposing of used oil and lubricants the local laws and regulations are to be followed
without fail. The proprietor is responsible for proper waste disposal.
EWAGB0BB
Chapter 2 - 9
0414MC
2.1.6 Safety regulations for the Modular Airmould® System
The Modular Airmould® System (option) has been designed and built to the currently
applicable European Standard EN ISO 12100, EN 60204, Part 1, and EN ISO 4414 and is
safe to operate. Hazards may still arise from the Modular Airmould® System if it is operated by
untrained personnel improperly or for an unsuitable purpose. For this reason, all work involving
installation, dismantling, modifications and maintenance may only be carried out by personnel
trained in this field.
The Modular Airmould® System must be relieved from pressure according to the descriptions
in the operating manual for all work involving installation, dismantling, modifications and
maintenance.
Only those hose assemblies may be used which meet at least the requirements of DIN EN 853
(Type 2SN) whereas the outer layer must be permeable to nitrogen. The safety regulations
according to DIN 20066 and EN 201 must also be followed.
Only hose assemblies with fittings that were either supplied or specified by Wittmann Battenfeld
GmbH should be implemented.
Only hose assemblies with fittings which comply with or exceed DIN ISO 12151-2 may be used.
Hose assemblies must be mounted so that:
• Their natural position and movement are not hindered.
• In operation they are not subject to external stresses from tension, torsion or crushing.
• They are protected from external mechanical, thermal and chemical damage.
Never paint hose assemblies.
Hose assemblies must not be bent to a tighter bending radius than the minimum specified by
the manufacturer.
Torque settings of the union nut must be reached at 1 to 1 1/2 turns of the union nut.
To ensure the proper serviceability of hose assemblies they must be assembled according to
DIN 20066.
After fitting or renewal, hose assemblies must be secured so that any hazard on bursting or
blowing off is prevented.
After fitting or replacing hose assemblies, the serviceability is to be checked by a trained and
skilled technician.
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Nitrogen pipelines must meet or exceed the minimum requirements of DIN EN 10305-E
"Seamless cold-drawn tubes for hydraulic and pneumatic pressure lines" and DIN EN 10025
"Hot-rolled plain steel products", material code number 1.0255 (St 37-4).
The screw connection parts must meet the minimum requirements of DIN 2353, EN ISO 8434-1
"Solderless pipe connections with cutting ring" (Heavy Series S).
Pipe fittings must be designed to DIN 3859-1.
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Chapter 2 - 11
0414MC
2.1.7 Safety regulations for moulding compounds
The machine is intended exclusively for the processing of moulding compound as stated in the
chapter "General information". Any other use is considered improper and any loss damage or
injury arising is the responsibility of the proprietor. The manufacturer can accept no liability.
It is the operator's duty to ensure that no drawn in material or explosive air mixtures may be
near the heating of the screw barrel or the internal cooling of the screw barrel (option) and the
inlet area of the radial fans (option) for the outside cooling of the screw barrel.
The operator has to make sure that the radial fans may only be used in a technically faultless
condition and with undamaged electrics.
When processing moulding compounds which give rise to harmful gases, dusts or vapours, the
proprietor of the machine has a duty to provide suitable extraction for the protection of operating
personnel.
Some moulding compounds, if they are not properly dried, may spit material from the nozzle.
Follow the moulding compound manufacturers' instructions.
It is the operator's duty to ensure that the heating of the shut-off nozzle will be reduced before
shutting the machine down. Gases are formed if certain types of moulded compounds remain
for a longer period of time in out of operation heated shut-off nozzle. These gases can escape
explosively through the discharge bore of the shut-off nozzle.
There is a burning hazard at operating temperature from:
• Barrel nozzles, mould nozzles.
• Plasticised moulding compound emerging from the nozzle.
Wear appropriate personal protective equipment.
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2.1.8 Safety regulations for electrics
The electrical equipment on the machine is designed and built to the currently valid standards
DIN EN 60204-1 and EN 61000-6-4, EN 61000-6-2 and is safe to operate. Hazards can,
however, arise from the electrical system of this machine if it is improperly used by untrained
personnel or is used for purposes for which it is not designed. Thus all work involving
installation, dismantling, modification and maintenance may only be carried out by a qualified
electrician (as defined in DIN VDE 0105, EN 50110 or DIN EN 60204-1).
The electrical equipment may only be connected to a mains supply which corresponds in terms
of current type, voltage and frequency to the specifications on the machine's electrical plate.
The electrical supply lines must meet the requirements.
The machine must be switched off at the main switch before all work involving installation,
dismantling, modification and maintenance. Check the electrical equipment for lack of voltage,
then earth it and and short it out.
The mains supply and power heating terminals remain live even when the machine is switched
off.
The electrical equipment is to be checked at regular intervals. Defects such as loose
connections or scorched cables must be immediately remedied.
For reasons of safety, the operator must log off from the control unit after finishing the setting
mode in order to prevent unauthorised persons from data entry.
At the end of installation work, for safety reasons, the keys should be removed from all key-
operated switches and kept in a safe place.
Legal requirements and regulations must be followed in all work involving installation,
dismantling, modification and maintenance.
Not for hand-held electrical

appliances suitably! GB
No FI-protective circuit!
Danger by current impact! At sockets with this specification plate no portable hand-held
electrical appliances (e.g. hand drill) may be attached.
Only attach electrical appliances according to the intended use of the sockets.
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Chapter 2 - 13
0414MC
2.1.9 Safety regulations for changing nozzle, screw and barrel
The nozzle, nozzle body, screw and screw barrel may be assembled or disassembled by trained
and authorised persons only.
It is absolutely necessary to meet the torque settings (according to the table) of the nozzle and
the nozzle body.
When installing a complete injection unit, only parts supplied or specified by Wittmann
Battenfeld GmbH may be used.
When fitting or removing the nozzle, screw or screw barrel it is essential to activate and use the
machine without the guarding on the injection unit.
The proprietor therefore has a duty to ensure that the danger zone is adequately protected and
that no unauthorised persons enter this zone.
Before moving the injection or nozzle contact cylinders with their guarding on the injection unit
removed it must be ensured that no tools or other materials are left on the machine.
Whilst moving the injection plunger or nozzle contact cylinder with the injection unit guarding
removed, the operator must maintain a safe distance.
Immediately after moving the injection or nozzle contact cylinders with their injection unit
guarding removed, the machine must be switched off again and secured against accidental
reconnection.
If proper procedures are not followed during mounting or disassembly or when touching nozzle,
screw, screw barrel, or its heating elements, there will be the risk of injury and burning hazards.
Wear appropriate personal protective equipment.
When fitting or removing the nozzle, screw or screw barrel, no tools may be used which could
cause damage to these components.
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2.1.10 Safety instructions Environment
Lubricants and hydraulic oils are environmentally hazardous products. For this reason, the local
environmental laws and regulations concerning water, building, waste, transport, trade and
safety at work must be observed.
These areas of legislation include the fields of transportation, storage and waste disposal.
Even the strictest compliance with all laws and regulations does not preclude accidents with
lubricants. In such cases the appropriate authorities (Water Board, Police, Fire Brigade) must
be notified immediately. The amount of lubricant discharged before notification is required varies
from place to place.
There is therefore a need to make contingency plans for preventive measures in the case of
any incident with oil. This includes the existence of such a plan itself, that sufficient oil absorbing
medium is in stock, that drains can be closed off and that tools and materials are available to
prevent the spilled oil from escaping.
Request safety specification sheets according to ISO 11014 (safety specification sheet for
chemical products) for your products from your lubricant supplier.
These cover:
• Chemical and physical properties.
• Protective measures, storage and handling.
• Measures to be taken in the event of accidents and fires.
When disposing of electrical and electronic components, the local laws and regulations are to
be observed.
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Chapter 2 - 15
0414MC
2.2 Table for risk assessment
Reasonably foreseeable inappropriate installation / use
Case Hazard Consequence Measures *)

Overload of the machine;
possibly fire or explosion Warnings and allowed
Only if the warnings in the
1 Use of unsuitable materials risk, hazard to health due to material range in the
operating manual are ignored
the emission of hazardous operating manual
substances
Overload of the machine, un- Damage to machine
Use of unsuitable moulds; Instructions in the operating
2 certain operating conditions, components, shortcomings in
mould not installed manual
escape of hot material production
Burning hazard if
Guardings are not available High surface temperatures, accidentally touched or
Warnings, labels, instructions
3 and the monitoring switches moving parts during closing during maintenance work,
in the operating manual
are disabled movement crushing hazard from closing
movement.
Instructions in the operating
4 Operating error Loss of machine function
manual
Reasonably foreseeable faults in installation and electrical connection
Case Hazard Consequence Measures *)

Electrical supply (voltage, Instructions in the operating
1 No proper functioning Permanent machine damage
frequency, cable size) manual
Unsuitable coolant (Water Instructions in the operating
2 Blockage, overheating Permanent machine damage
flow rate, pressure) manual
*) The given measures should only be carried out by trained operators / setters.
EWAGB0BB
3 Technical data
The chapter "Technical data" contains all the technical data required for normal installation,
commissioning and operation of the injection moulding machine.
3.1 General information

Machine type / control see cover sheet
Machine No. / year of construction see cover sheet
Machine weight gross / nett see foundation and installation plan
Main dimensions of the IMM see foundation and installation plan
Noise level (DIN EN ISO 3744 46) 72 dB(A)
3.2 Hydraulic equipment

Oil temperature min / max (HLP 46) min 35 °C (95 °F); max. 65 °C (149 °F)
Oil temperature min / max (HLP 32) min 25 °C (77 °F); max. 55 °C (131 °F)
Oil cooling trigger temperature (HLP 46) 45 °C (113 °F)
Oil cooling trigger temperature (HLP 32) 35 °C (95 °F)
Ambient temperature: +15 - +40 °C (+59 - +104°F)
3.3 Electrical equipment

Power, hydraulic pump see foundation and installation plan
Motor voltage see electrical plate
frequency see electrical plate
Screw barrel temperature max. 350 °C (350,00 °C) (option 500 °C, 500,00 °C)
3.4 Water system

Oil cooler: Cooling water consumption aprox. 0.5 - 1.5 m3/ h (0.65 -1.96 cu yd)
Cooling water supply max. 22 °C ( 72 °F) NW 1"
Oil cooler amplified: Cooling water consumption aprox. 0.1 - 1.5 m3/ h (0.13 -1.96 cu yd)
Cooling water supply max. 30 °C ( 86 °F) NW 1"
Cooling water distributor:Cooling water supply Ø 3/4", max. 10 bar (max. 145 psi)
Cooling water return Ø 3/4"
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0115TW Chapter 3 - 1
3.5 Pump output
Pump capacity (litres) 35 50 60 80 95
SmartPower 25/60 X
SmartPower 25/130 X
SmartPower 35/60 X
SmartPower 35/130 X
SmartPower 50/60 X
SmartPower 50/130 X
SmartPower 50/210 X
SmartPower 50/350 X
SmartPower 60/60 X
SmartPower 60/130 X
SmartPower 60/210 X
SmartPower 60/350 X
SmartPower 80/130 X
SmartPower 80/210 X
SmartPower 80/350 X
SmartPower 80/525 X
SmartPower 90/130 X
SmartPower 90/210 X
SmartPower 90/350 X
SmartPower 90/525 X
SmartPower 110/210 X
Power kW 7.5 11 15 18.5 22
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3.6 Injection unit
SmartPower 25/35
Injection unit 60 130
Screw diameter mm 14 18 22 18 22 25 30
Screw stroke mm 90 110 125
Screw L/D ratio 20 20 22
Calculated stroke volume cm3 13,9 22,9 34,2 28 41,8 61,4 88,4
Specific injection pressure bar 3.000 2.593 1.736 3.000 2.864 2.218 1.540
Max. screw rotational speed min–1 436 278
Max. plastification flow (PS) 2) g/s 1,5 4,4 6,4 2,8 4,1 7,5 10,7
Screw torque Nm 65 140 231 140 238 357
Nozzle stroke / Nozzle force mm/kN 250/47 250/47
Injection flow in the open cm3/s 28,6 47,3 70,6 28,6 42,8 55,2 79,5
Injection flow in the open with cm /s
3 49 81 121 49,1 73,3 94,7 136
additional pump (option)
Injection flow in the open with cm3/s 65 108 161 77,7 116 150 216
accumulator (option)
Barrel heating power kW 2,9 5,5 6,3 5,5 6,3 9 10,4
Number of heating zones incl. nozzle 4 4
2) according to WITTMANN BATTENFELD standard
SmartPower 50/60
Injection unit 60 130 210 350
Screw diameter mm 14 18 22 18 22 25 30 25 30 35 30 35 40
Screw stroke mm 90 110 125 150 175
Screw L/D ratio 20 20 22 22 22
Calculated stroke volume cm3 13,9 22,9 34,2 28 41,8 61,4 88,4 73,6 106 144 123 169 220
Specific injection pressure bar 3.000 2.593 1.736 3.000 2.864 2.218 1.540 2.940 2.042 1.500 2.835 2.083 1.595
Max. screw rotational speed min–1 623 398 310 298
Max. plastification flow (PS) 2) g/s 1,9 6,2 9 4 5,8 10,5 15,4 8,2 12 18,6 11,6 17,9 28,5
Screw torque Nm 90 140 231 140 238 357 420 490 621
Nozzle stroke / Nozzle force mm/kN 250/47 250/47 250/86 250/86
Injection flow in the open cm3/s 40,8 67,5 101 40,9 61,1 78,9 114 59,5 85,7 117 74,1 101 132
3 65,3 108 161 65,5 97,8 126 182 95,2 137 187 111 151 198
Injection flow in the open with cm3/s 65,3 108 161 77,7 116 150 216 155 223 303 161 218 285
Barrel heating power kW 2,9 5,5 6,3 5,5 6,3 9 10,4 9 10,4 10,4 10,4 10,4 12,9
Number of heating zones incl. nozzle 4 4 4 4
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SmartPower 80/90
Screw diameter mm 18 22 25 30 25 30 35 30 35 40 35 40 45
Screw stroke mm 110 125 150 175 200
Screw L/D ratio 20 22 22 22 22
Calculated stroke volume cm3 28 41,8 61,4 88,4 73,6 106 144 123 169 220 193 251 318
Specific injection pressure bar 3.000 2.864 2.218 1.540 2.940 2.042 1.500 2.835 2.083 1.595 2.743 2.100 1.659
Max. plastification flow (PS) 2) g/s 4,8 6,9 12,6 18,5 9,9 14,4 22,3 11,6 17,9 28,5 19,1 30,4 39,7
Screw torque Nm 140 238 357 420 490 621 770
Injection flow in the open cm3/s 49,1 73,4 94,7 136 71,4 103 140 74,1 101 132 102 133 169
3 77,7 116 150 216 113 163 222 117 160 209 147 192 243
Injection flow in the open with cm3/s 77,7 116 150 216 155 223 303 216 294 384 223 292 369
Barrel heating power kW 5,5 6,3 9 10,4 9 10,4 10,4 10,4 10,4 12,9 11,5 14 17,3
Number of heating zones incl. nozzle 4 4 4 4
SmartPower 110/120
Screw diameter mm 25 30 35 30 35 40 35 40 45 40 45 50
Screw stroke mm 150 175 200 225
Screw L/D ratio 22 22 22 22
Calculated stroke volume cm3 73,6 106 144 123 169 220 193 251 318 283 358 442
Specific injection pressure bar 2.940 2.042 1.500 2.835 2.083 1.595 2.743 2.100 1.659 2.678 2.116 1.714
Max. plastification flow (PS) 2) g/s 13,1 19,2 29,7 15,4 23,8 38 19,1 30,4 39,7 27,9 36,3 43,9
Screw torque Nm 420 490 621 770 998
Injection flow in the open cm3/s 95,2 137 187 98,8 134 176 102 133 169 124 157 194
Injection flow in the open with cm /s3 137 197 268 142 193 252 147 192 243 170 215 266
Injection flow in the open with cm3/s 155 223 303 216 294 384 223 292 369 229 290 357
Barrel heating power kW 9 10,4 10,4 10,4 10,4 12,9 11,5 14 17,3 14 17,3 21,9
Number of heating zones incl. nozzle 4 4 4 4 4 5
SM1GB0CA
3.7 Clamping unit
SmartPower 25 / 35
Clamping unit SmartPower 25 SmartPower 35
Clamping force kN 250 350

Distance between tiebars mm x mm 320 x 270
Min. mould mounting height mm 200
Opening stroke / Opening force mm/kN 350/25
Max. platen distance mm 550
Ejector stroke / Ejector force mm/kN 100/26,4
Dry cycle time1) s-mm 1,6 – 189
Max. mould weight 4) kg 500
Min. mould dimensions mm x mm 196 x 196
1) theoretical, according to EUROMAP 6 4) Max. 2/3 on clamping platen
SmartPower 50/60

Max. mould weight 4) kg/mm 700
SmartPower 80 / 90

Max. mould weight 4) kg 900
SM1GB0CA
SmartPower 110/120

Max. mould weight 4) kg 1.100
Insulating plates, adapter plates with T-slots, magnetic quick action mould mounting systems,
etc. will reduce the standard mould mounting height. For the mould mounting dimensions
relevant to your IMM please refer to the dimension diagram at the end of this chapter.
3.8 Mould dimensions

Minimum mould dimensions
With the central clamping cylinder and the construction of the moving platens, the Mouldfix
system ensures gentle application and even distribution of clamping force.
These functions can only be fulfilled if the minimum dimensions of the mould do not fall below a
certain minimum, so that "wrap-round" of the mould mounting platens is kept within acceptable
limits.
Since the dimensional accuracy of the injection moulded parts, the loading on the mould and
the mould’s function especially with complex tooling (multi-plate tools, side actions) are affected
by the wrap-round of the mould mounting platens, keeping to these guidelines will ensure that
unacceptable overloading of the clamping unit and the mould are avoided.
The minimum mould dimensions specified in the table (clamping unit) should be observed,
bearing in mind the required clamping force in respect of mould loading and energy
consumption.
Also take care that, with maximum mould weight, 2/3 of the weight is mounted on the clamping
platen.
Special attention must be paid to off-centre moulds and to parallelism of the mould and
mould parting surfaces. Any deficiency here can cause deformation of both the mould and
the clamping unit, with a very detrimental effect on the service life of sealing and guiding
components.
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3.9 Conversion table for shot weights
The maximum shot weights (g / oz) are calculated by multiplying the theoretical shot volume
(cm3 / cu inch) by the factors given above. The grey fields contain the factors for thermoset
plastics.
Material Factor Material Factor
ABS 0.88 PP + 40 % Talcum 0.98

CA 1.02 PP + 20% GF 0.85
CAB 0.97 PS 0.91
PA 0.91 Rigid PVC 1.12
PC 0.97 Soft PVC 1.02
PE 0.71 SAN 0.88
PMMA 0.94 SB 0.88
POM 1.15
PP 0.73 PF 1.3
PP + 20% Talcum 0.85 UP 1.6
3.10 Weights of screws and barrels

Load requirements for screw barrel including screw when performing a screw and barrel
change.
Injection unit Screw diameter Weight

[mm] [inch] [kg] [lbs]
14 0.55 40 88
18 0.71 40 88
22 0.87 40 88
25 0.98 70 154
60 - 750 30 1.18 70 154
35 1.38 100 220
40 1.57 115 243
45 1.77 125 276
50 1.97 170 375
SM1GB0CA
3.11 Torque settings for bolts
Tightening torque Assembly
Thread Nominal size
Property class 8.8
[NM] [lbf ft]
M4 3 2
M5 5.5 4
M6 9.5 7
M8 23 17
M10 42 31
M12 72 53
M14 114 84
M16 174 128
M20 340 251
M24 580 428
M27 855 631
M27x2 900 664
M30 1160 856
m33X2 1680 1239
m36 2030 1497
m36X" 2200 1623
m39 2620 1932
m42 3240 2390
m48 4890 3607
The torque settings are listed in the spare parts list together with the screws showing different
settings. These settings must absolutely be kept.
The torques are based on a frictional factor of 0.10 (μm total) for untreated, Molykote lubricated
and cadmium electroplated surfaces, but not for slightly oiled ones.
SM1GB0CA
3.12 Torque settings for the fastening screws of the screw barrel
head
These torque settings are valid for socket head cap screws (1) for fastening the nozzle head (2).
Further information on tensile strengths etc. can be found in the spare parts lists.
Standard version

Thread Nominal size
Property class 12.9
[NM] [lbf ft]
M8 35 26
M12 130 96
M16 300 221
M20 550 406
M24 1000 738 1
M30 2000 1475
High temperature heater bands

2
Thread Nominal size
Property class GB
[NM] [lbf ft]
M8 25 18
M12 90 66
M16 200 148
M20 350 258
M24 650 479
M30 1280 944
3.13 Layout
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SM1GB0CA
4 Transport - Installation

After delivery of the injection moulding machine, it should be checked immediately for any
damage and/or for completeness. If necessary, they must be reported immediately to the
transport company. Putting into operation must not take place if a transport damage which will
restrict proper operation is assumed.
The machine delivery kit includes:
• Operating instructions
• Levelling mounts (option).
All the keys etc. for the switch cabinet, guarding etc. are to be found attached to the main
switch.
We would recommend installation of the machine to be carried out by personnel of the Wittmann
Battenfeld GmbH. We can accept no responsibility for damage resulting from improper handling.
The foundation plan and installation plan can be found in the chapter "Technical Data". This
chapter includes, amongst other information, the machine weights and dimensions. These must
be considered when installing the machine.
The installation drawings have been simplified for clarity.
4.2 Unpacking / storage

Please observe the rules of environmental protection. Ensure that all packing material
will be disposed of properly and environmentally friendly.
The machine is packed as standard to withstand transportation without damage. However it

should be commissioned immediately after handover from the transport company.
If it is to be stored for a longer period, our customer service department has to be contacted.
4.3 Unloading
Trouble free operation and some clauses of the guarantee are conditional upon proper
unloading!
The machine may only be lifted and moved horizontally and using the provided lifting
and transport elements. It is essential that the lifting gear is prevented from slipping!
Only nylon slings of sufficient length are to be used; other types of lifting gear may
damage the tiebars.
The safe working load of the crane and the slings must equal or exceed the weight of the
machine. See chapter "Technical data", Foundation and installation plan for details!
Follow without fail the transport plan fixed to the machine!
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Chapter 4 - 1
0115TW
No persons may stand or linger under the suspended load!
The complete machine may only be placed on a level surface capable of supporting the
load of the machine.
Trouble free operation can not be guaranteed if the complete machine is placed on an
uneven floor.
If there is no level surface, a foundation must be built for the machine according to the
"Foundation and Installation Plan", see "Technical Data" chapter, to provide a level base.
If transport to the final location is impossible with cranes, the machine must be supported under
its entire base for moving across the floor.
4.4 Space requirement plan

The exact space requirement can be taken from the machine layout in the "Technical Data"
chapter.
A minimum space of 1.3 m (52 inch) must be allowed around the machine for maintenance
work.
SM1GB0DA
4.5 Transporting the machine
This machine is equipped with a transport monitoring system.

Please handle this machine according to the transport instructions.
Improper handling causes a reaction of the indicator. It is absolutely necessary to state
in the transport documents whether the indicator is missing or has reacted.
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Chapter 4 - 3
0115TW
For installation, dismantling, modification, adaptation, and maintenance, work parts,
components or the entire machine have to be secured and carefully attached to the
lifting gear so as to prevent any dangers from arising. Only use appropriate lifting gear in
proper working order with sufficient carrying force. Personnel or other persons must by
no means stand or work under suspended loads.
Loads may only be fastened, secured and transported by experienced, authorised and
trained personnel.
Before installation of the machine the safety measures detailed in DIN EN 292-2, Para.
6.1.2 must be complied with.
If the transport plans do not agree with the following descriptions and diagrams, the
transport plans in the "Technical Data" chapter are to be taken as definitive!
SmartPower 25-120
Fork lift transport
Crane transport with one lifting gear.
SM1GB0DA
Machine weight
SmartPower machine weight

TYPE kg lbs
SmartPower 25/60 2500 5513
SmartPower 25/130 2500 5513
SmartPower 35/60 2500 5513
SmartPower 35/130 2500 5513
SmartPower 50/60 3000 6615
SmartPower 50/130 3000 6615
SmartPower 50/210 3100 6836
SmartPower 50/350 3100 6836
SmartPower 60/60 3000 6615
SmartPower 60/130 3000 6615
SmartPower 60/210 3100 6836
SmartPower 60/350 3100 6836
SmartPower 80/130 4000 8820
SmartPower 80/210 4100 9041
SmartPower 80/350 4100 9041
SmartPower 80/525 4200 9261
SmartPower 90/130 4000 8820
SmartPower 90/210 4100 9041
SmartPower 90/350 4100 9041
SmartPower 90/525 4200 9261
SmartPower 110/210 4500 9923
SmartPower 110/350 4500 9923
SmartPower 110/525 4600 10143
SmartPower 110/750 4600 10143
SmartPower 120/210 4500 9923
SmartPower 120/350 4500 9923
SmartPower 120/525 4600 10143
SmartPower 120/750 4600 10143
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Chapter 4 - 5
0115TW
4.6 Erecting the machine
The injection moulding machine may only be installed in a dry, dust-free environment
above freezing point. The machine body must completely rest on the levelling mounts or
the wedge elements.
Adjustment of the oscillating elements

Adjustment is made by means of the hexagon bolt. A hexagonal nut (2) is used as a lock nut to
fix the height adjusted by the screw (1).
Type Height Setting range SmartPower 25 - 120
Oscillating element Ø 160/M16 59 mm [2.32 inch] 30 mm [1.18 inch] 8
SM1GB0DA
4.7 Transportation device
The transportation devices described in this paragraph must be removed before
commissioning the machine and MUST be replaced before the IMM is moved!
SmartPower safety gate

The clamping unit's safety gates on the operator's side and the rear are opened and secured by
a rope around the machine frame tied to each handle.
SM1GB0DA
Chapter 4 - 7
0115TW
4.8 Removing preservative agents
ATTENTION
All bare parts are protected with a corrosion inhibitor STALOC Korrotech 3000 SQ1003
to protect the machine. When commissioning the injection moulding machine, it is
absolutely necessary that the preservative agents are removed exactly and completely,
e.g.: with STALOC SQ200, multi-function oil (WD40, Castrol DWF..), nitro, degreasing
agent (brake cleaner). The preservative agent will stick in the guide rails if just one
single stroke was made without having removed the preservative agent. Grinding of the
guide rails will then be inevitable.
Small components delivered with the IMM such as screw tips and stop rings are
protected by wax dipping. The wax coating should be removed before use.
ATTENTION
Do NOT protect the spindle with a preservative agent or remove the corrosion protection!
If corrosion protection is required, use the prescribed operation grease.
These cleaning fluids are considered hazardous to health and are flammable. Follow the
manufacturers’ instructions!
The local regulations must be observed when disposing of these liquids and cloths
soaked in them!
Injection unit 60-750
1 Nozzle contact cylinder piston rods

2 Guide rails Injection unit
3 Hopper base plate
4 Screw barrel, shaft and mounts
SM1GB0DA
Clamping unit 25-120
1
2
1 Mould mounting surfaces

2 Ejector coupling and guides
3 Guide rails of the clamping platen
SM1GB0DA
Chapter 4 - 9
0115TW
4.9 Levelling the machine
A machine spirit level with an accuracy of 0.1 mm / m (0.004 inch / 3.281 ft) and a true straight-
edge are essential for levelling the machine. In addition, the machine must be equipped with
levelling mounts / wedge elements (option).
The machine level (1) is laid across the clamping unit slideways (2) on the straight-edge (3) and
the machine is levelled lengthways and across to 0.2 mm/m (0.008 inch / 3.281 ft) by means of
the levelling mounts / wedge elements.
1
3
Injection unit
The centricity of the nozzle has been set in the factory, but must still be checked after moving
the machine, and readjusted if necessary.
• Fill with hydraulic oil; see "Hydraulic unit".

• Connect power; see "Electrical equipment" paragraph
• Select "Setting" mode.
• Move the injection unit back until the nozzle is flush with the near face of the nozzle
platen.
• Switch off at the main switch and secure against accidental reconnection.
• Adjusting rules for the nozzle centre see Chapter "Strucuture and Function"
SM1GB0DA
4.10 Hydraulic system
Work at the hydraulic system may only be carried out by a skilled hydraulic technician!
If the hydraulic system is not relieved of pressure before work is started it may empty
explosively with the risk of damage and injury!
If the clamping platen, nozzle and screw are not in one of their end positions then the hydraulic
system is relieved from pressure. Any residual pressure can be released by carefully loosening
(but not completely undoing) a hydraulic screw connection. In case of hydraulic systems with
pressure vessels (option) you have to wait until the system has been completely relieved from
pressure. See also the paragraph "Checking the hydraulic pressure" in chapter "Maintenance".
Turn off the mains switch and secure it against accidental reconnection.
4.10.1 Filling
The oil filler neck (1) is located behind the clamping unit.
SmartPower 25 - 120
CAUTION
The machine’s hydraulic unit requires oil of the cleanliness class 17/15/12 according
to ISO 4406. Contamination above this cleanliness class by improper filling or use of
unsuitable hydraulic oil will invalidate the guarantee!
If hydraulic oil becomes contaminated with water it will be of inferior quality and must
not be used any further!
SM1GB0EA
0115TW Chapter 4.10 - 1
The hydraulic tank may only be filled with hydraulic oil as detailed in the "Maintenance" chapter.
The required volume of oil is detailed in the machine layout (chapter "Technical Data").
CAUTION
Test the hydraulic oil for the possible ingress of water!
Never switch the machine on without hydraulic oil. Even the shortest period of running
will damage hydraulic equipment!
When filling for the first time the following sequence must be followed without fail:
• Clean the filler screws and the screw plugs on transport and storage containers.
• Verify the grade of oil; see "Maintenance" chapter.
• Prefilter the hydraulic oil through a mobile filtration unit with a 3 μm (118.11 μinch) mesh.
• Make sure that the main switch is switched off and secured against accidental
reconnection.
• Remove guarding if necessary.
• Clean around the filler and venting filter.
• Remove the lock of the filler and venting filter (the filter screen must remain in place for
filling).
Fill the oil tankfor the first time with "clamping side open"
• Fill hydraulic tank to the maximum oil level through a mobile filtration unit with 3 μm
MAX (118.11 μinch) mesh until the float in the oil sight glass has reached the max. marker. The
oil sight glass is located at the clamping side front of the machine.
MIN
50 mm (1.97 inch)
Switching level
Fill the oil tank for the first time with "Clamping side open" (e.g. with mounted mould).
• Fill hydraulic tank to the maximum oil level through a mobile filtration unit with 3 μm
(118.11 μinch) mesh until the float in the oil sight glass is located above the min. marker.
The oil sight glass is located at the clamping side front of the machine.
HM_1014.PMP
In this situation, never fill in oil up to the max. marker.
CAUTION
Before switching on the machine, the hydraulic oil should be allowed to stand for approx.
1 hour to let the air trapped during filling escape!
SM1GB0EA
Chapter 4.10 - 2 0115TW
4.10.2 Commissioning of the hydraulic pump
• Activation of the pump rinsing program for pump system 1 and pump system 2 if present
(option).
UNILOG B6
CAUTION
Before switching on the hydraulic pump the hydraulic motor’s direction of rotation
should be checked!
• Start the machine

• If there is air present in the pump system, e.g. due to a pump or oil change, activate this
program to eliminate the air from the system.
• The pump rinsing program is to be activated for 20 minutes approx. The program has to
be deactivated afterwards.
• The oil heating starts if the oil operating temperature has not been reached with the pump
rinsing program.
• If the clamping unit is in the "open" position, move the clamping unit to the front position
(refill oil if necessary) and carry out a complete dry cycle (oil is distributed in the system).
• If the clamping unit is in the "closed" position, slowly open the clamping unit and observe
the oil sight glass. If the oil level exceeds the visible part of the gauge, oil must be
removed to carry out a complete dry cycle (oil is distributed in the system).
• If the oil level is lower than the min. marker after this process and the oil level detector
emits an error message, only fill in oil until the error message can be acknowledged.
• During machine operation, the oil level should be between the max. and the min. marker.
SM1GB0EA
0115TW Chapter 4.10 - 3
If the tank is filled above the maximum level, hydraulic oil will come out of the venting
filter! In this case, the suction pipe and the filter housing have to be cleaned and the filter
insert has to be replaced.
• Remount the filling and venting filter onto the pipe socket.
• Attach guarding if necessary.
4.10.3 Deaeration
After filling the hydraulic tank air must be bled from the hydraulic system.
• Connect power; see "Electrical equipment" paragraph.
• Connect cooling water; see "Water system" paragraph.
• Press the "Hydraulic start" key to switch on the hydraulics.
• Press the "Setting" key.
• Open and close all safety gates.
• Drive the clamping platen, nozzle and screw forward and backward over their whole
stroke several times.
Bleeding is carried out effectively when no foam appears in the hydraulic tank, movements are
smooth and there are no strange noises.
The oil level should be checked after bleeding and topped up if necessary. Care must be taken
to use the same oil type.
Any oil leaks arising after a few operating hours are usually cured simply by tightening the screw
connections.
4.10.4 Pressure vessel

Pressure vessels (option) integrated into the hydraulic system allow increased injection output.
Work on plants with pressure vessels may only be carried out by a specially trained
technician!
Work on plants with pressure vessels (repairs, connections of a pressure gauge or the
like) must not be carried out until the hydraulic pressure (oil) has been released!
Risk of explosion! Only use nitrogen "N2" as gas!
Before starting up the machine the nitrogen pressure within the pressure vessel must be
checked. In case the nitrogen pressure falls short of the indicated value (see name plate),
nitrogen has to be refilled.
Pressure vessels are subject to the safety regulations applicable at the place of use. Before
starting up the machine, they have to be accepted by the technical standards organisation (e.g.
TÜV) responsible in the proprietor’s region.
The proprietor of pressure vessels is responsible for ensuring the proper condition, operation
and monitoring.
SM1GB0EA
Chapter 4.10 - 4 0115TW
Neither welding nor soldering nor any mechanical processing may be performed on the
pressure vessels. Improper repairs can cause severe accidents and may only be carried out by
authorised customer service personnel.
Replenishing, reducing and testing the nitrogen pressure
CAUTION
The nitrogen pressure changes temperature dependently. For this reason, inspections
should always be carried out under equal temperature conditions. After filling or
discharging nitrogen please wait 5 minutes approx. until the temperature has been
balanced. Check the gas pressure afterwards!
During each check nitrogen will escape through the filling unit. This will reduce the
nitrogen pressure, especially in case of small pressure vessels!
The pressure within the mobile nitrogen cylinder (for filling the pressure vessel) may not
exceed the maximum permissible operating pressure of the machine’s pressure vessel
or the pressure gauge. Otherwise a pressure reducer has to be inserted between the
mobile pressure cylinder and the filler!
Please keep all certificates in a safe place!
When demanding certficates later on, please state the contents, the factory number and the
year of manufacture of the vessel. These data is embossed on both ends of the vessel.
2
1 3 1- Non-return valve (valve insert)
2- Button
4 3- Valve gate
5 4- Pressure pin
5- Venting valve
9 6 6- Union nut
7- Seal element
10 7 8- Connection piece (SAE 7/8" - 14UNF -2B)
9- Gas filling valve
8 10 - bubble accumulator
1 Screw a pressure gauge connection-Hose assembly Nominal diameter ND2; G 1/4

(option) to the fitting of a pressure gauge, 0 to 600 bar / 8700 psi (option), not included in
the standard delivery
2 Clean the surroundings of the miniature measuring connection at the hydraulic block of
the pressure vessel.
3 Remove the sealing cap of the miniature measuring connection.
4 Screw in the fitting of the pressure gauge connection-hose assembly.
5 Switch off the machine at the main switch.
6 Wait for the pressure of the hydraulic oil within the pressure vessel to be reduced (until
the pressure gauge indicates 0 bar / psi).
7 Unscrew the covering cap(s) of the gas filling valve.
SM1GB0EA
0115TW Chapter 4.10 - 5
8 Screw the filler unit to the gas filling valve.
9 Check whether the venting valve of the filler unit is closed.
10 Screw the hose assembly’s connecting piece to the nitrogen bottle.
11 Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly flowing
into the pressure vessel (for the filling pressure please refer to the hydraulic plan or the
respective label).
12 Close the shut-off valve after reaching the desired nitrogen pressure.
13 Use the venting valve to close the filling hose.
14 Press the button of the filler unit, release it and read off the nitrogen pressure at the
pressure gauge.
15 In case the nitrogen pressure is too high, carefully press the pressure pin after opening
the venting valve to reduce the pressure.
Steps 10, 11 and 12 will be omitted when reducing or checking the pressure.
4.10.5 Bypass filtration unit

By using a bypass filtration unit the machine’s downtime will be considerably reduced by having
longer service and maintenance intervals.
For this purpose connection points on the back of the tank for the return line from the bypass
filtration unit and the flow from the hydraulic tank to the bypass filtration unit are provided.
The bypass filtration unit must be connected with the hydraulic tank empty if the shut-off valves
(option) are not fitted.
After proper connection of the supply and return lines, the shut-off valves must be opened
before the bypass filtration unit is started up.
4.10.6 Core puller (option)

see Chapter "Strucuture and Function"
Hydraulic core pullers may only be fitted and put into operation by a hydraulic
technician! The safety regulations in the chapter "Safety" are to be followed without fail!
SM1GB0EA
Chapter 4.10 - 6 0115TW
4.11 Water system
ATTENTION
When installing water pipework note the corrosion stability of metallic materials against
water in accordance with DIN 50930!
4.11.1 Water quality

If there are deviations from the following guidelines, please contact our technical customer
service or one of our subsidiaries. The addresses can be found in the "Customer service"
chapter.
• pH value: 6,5 - 9
• Water hardness: < 1.8 mmol/l (681 ppm/gal)
• Solids: < 0.03 ‰ (30 ppm)
• Filter mesh: <100 μm (0.004 mm)
In the relation of solids content to water hardness, it should be noted that the harder the cooling
water is the lower the solids content has to be. If the level of suspended matter is over 0.03 ‰
(30 ppm), a water filter with a mesh size <100 μm (0.004 inch) must be fitted before the water
system.
It is also recommended to add a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579
from Henkel).
We recommend ethylene glycol type 420 as an antifreeze (60 % water and 40 % ethylene
glycol). This is suitable for a temperature range down to -30 °C (-22 °F) and is also a corrosion
inhibitor.
4.11.2 Cooling water connection
If the cooling system is not relieved of all pressure before work starts, there is a risk of
explosive emptying with possible damage or injury!
The cooling system for the IMM can also be run as a closed cooling system. The purest, most
chalk-free water should be used. The required nominal diameters of the hoses are quoted in the
chapter "Technical data". The bore of the flow and return lines must not be smaller than those of
the connections on the IMM.
EWAGBFC
Chapter 4.11 - 1
0115TW
4.11.3 Cooling water flow governor
The cooling water flow governor provide cooling water for various users, such as mould, screw
barrel, etc., from a common water supply. The cooling water flow rate and thus the temperatures
of the various consumers are controlled by the appropriate hand-wheels.
2
2
8
7
10
1
7
6
6
5
1
3
5
3 4
4
1 Common flow to cooling water flow governor

2 Common return from cooling water flow governor
3 Flow to user
4 Return from user
5 Hand-wheel to control cooling water flow to user
6 Hand-wheel to control cooling water return from user
7 Thermometer to show cooling water return temperature
8 Bobbin to show flow rate
9 Marker-ring to mark preset flow rate
10 Scale for setting
Burning hazard if touched! Wear suitable PPE with water temperatures above 50 °C
(122 °F)!
Injury hazard to operating and other personnel and possible damage to cooling water
flow governor if used at improper temperatures and pressures!
EWAGBFC
Chapter 4.11 - 2 0115TW

The cooling water pressure must be set for different temperatures according to the following
table:
Temperature max. pressure
40°C (104°F) 10 bar (145 psi)

60°C (140°F) 8 bar (116 psi)
80°C (176°F) 6 bar (87 psi)
• The cooling water hoses must be routed so that unhindered water supply and return are
ensured. Kinks and squeezing will prevent the optimised flow of the cooling water.
Water assemblies have to be expertly installed and laid. Fittings, length and cross
section have to meet the requirements!
• Make sure the hoses are long enough to allow for movement of the various units.
• The hoses must be suitable for the system pressure (max. 10 bar - 145 psi) and the
ambient temperatures used (max. 80 °C - 176 °F)
Before the cooling water flow governor is connected it must be ensured that the hand-wheels (5
and 6) are closed clockwise.
Next, the various users are connected to the cooling water flow governor (3 and 4).
Now the cooling water flow governor is connected to the cooling water system (1 and 2). By
turning the two hand-wheels (5 and 6) counterclockwise, the cooling water flow is opened and
the required flow rate can be set.
Using the marker ring (9), the required flow rate can be marked so that the desired flow rate can
be set again easily after a user has been turned off.
The flow rate set can be calculated from the bobbin's (8) position in the water stream and the
scale (10) using the following chart.
Flow range per circuit
Brass bobbin 0,5 - 10 l/min (0.11 - 2.20 imp.gal/min)

Temperature max. 80°C (176°F)
Pressure max. 10 bar (145 psi)
EWAGBFC
Chapter 4.11 - 3
0115TW
4.11.4 Oil cooling
The hydraulic oil is cooled in a heat exchanger. In which the cooling water is passed through a
cooling coil surrounded by the hydraulic oil.
A solenoid valve regulates the water flow. By allowing or interrupting the cooling water supply it
achieves a constant oil temperature.
A temperature sensor in the hydraulic tank measures and monitors the oil temperature and
sends the actual values to the IMM's control unit. This in turn orders the solenoid control valve
to be opened or closed.
Water assemblies for cooling the hydraulic system have to be expertly laid and installed.
Fittings, length and cross section have to meet the requirements!
• The cooling water hoses must be routed so that unhindered water supply and return are
ensured. Kinks and squeezing will prevent the optimised flow of the cooling water.
• The hoses must be suitable for the system pressure and the temperatures reached in
use.
The optimum efficiency of the injection moulding machine is at an oil temperature between
45 °C and 50 °C (113 °F and 122 °F) HLP 46, with HLP 32 between 35 °C and 40 °C (95 °F and
104°F). The maximum temperature of the supplied water must not exceed 22 °C, 72 °F, (30 °C,
86°F) with reinforced oil cooler.
Cooling water consumption conditions
Oil side max. 16 bar (232 psi)

Water side max. 10 bar (145 psi)
Water 2 m/s (1,8 yd/s)
Oil-Water 25°C (77°F)
4.11.5 Temperature control unit

Temperature control units (option) are used for liquid temperature conditioning of moulds,
barrels and screws.
Before operating the IMM its Safety regulations and those of the temperature control unit
must be observed without fail!
A temperature control unit may only be installed by a qualified electrician (according to

DIN VDE 0105, IEC 364 or equivalent)!
The installation, connection and commissioning of the temperature control unit are detailed in
the separate Operating Manual and in the corresponding wiring diagram in the "Spare parts /
Plans" chapter.
The standard location for the connection(s) is on the side of the switch cabinet.
EWAGBFC
Chapter 4.11 - 4 0115TW

4.12 Pneumatic system
Compressed air piping for the pneumatic system must be expertly laid and installed.
Fittings, length and cross section have to meet the requirements!
Work at the pneumatic system may only be carried out by a skilled pneumatic technician!
If the compressed air system is not relieved of all pressure before work starts, there is a
risk of explosive emptying with possible damage or injury!
4.12.1 Air supply unit
1
3
2
1 Setting knob pressure control valve

2 Condensate separator
3 Pressure gauge
4 Condensate reservoir
5 Drain screw
Turn pressure valve control knob (1) clockwise until the desired pressure (min. 6 bar - max. 10
bar / min. 87 psi - max. 145 psi) is shown on the pressure gauge (3).
SM1GB0GA
Chapter 4.12 - 1
0115TW
SM1GB0GA
Chapter 4.12 - 2 0115TW

The IMM may only be connected to a power supply which corresponds in phase, voltage and
frequency to the data given on the electrical specification plate.
Electrical installation may only be carried out by a qualified electrician (qualified to DIN
VDE 0105 or IEC 364 or equivalent)!
The electrical supply lines must be designed according to the specifications on the name
plate!
The currently valid local regulations on earthing and overload protection (overload,
wrong polarity protection) in TN-, IT- or TT supplies must be observed without fail by the
proprietor of the machine!
The protection for the phase conductors and the neutral conductor (IT-supply) must be
arranged to comply with the data on the electrical specification plate!
Connection as "Classical zerorising" (PEN-conductor) must not be used. PE-conductor
and N-conductor (if used) must always be connected separately!
The connecting terminals for drive and heating are located in the switch cabinet. The phase
conductors are connected directly to the main switch.
If the IMM is equipped with two separate power connections, they must not be connected to a
joint supply line. Hence there are four connection schemes:
1- Lead without neutral
1T2
1T1 1T3
4 (L1, L2, L3, PE)
2- Lead with neutral
1T2 N
1T1 1T3
5 (L1, L2, L3, N, E)
SM1GB0HA
0115TW Chapter 4.13 - 1
3- Separate leads for drive and heating without neutral
1T2 2T1 2T3

1T1 1T3 2T2
4 (L1, L2, L3, E)

4 (L1, L2, L3, E)
4- Separate leads for drive and heating with neutral
1T2 2T1 2T3

1T1 1T3 2T2 N
4 (L1, L2, L3, E)

5 (L1, L2, L3, N, E)
Checking the direction of rotation of the hydraulic pump’s drive

Before switching on the IMM it must be ensured that:
• The hydraulic system is sealed, the switch cabinet is closed, the hydraulic tank is filled
and the hydraulic pump(s) has/have been primed.
• The guarding and safety gates have been properly fitted and are closed.
CAUTION
The pump will not work correctly if the direction of rotation is wrong and the drive and
the hydraulic pump will fail!
• Connect the supplies as described in paragraph "Electrical equipment".
The hydraulic motor’s direction of rotation may only be tested by a qualified electrician!
• Open the electrical cabinet.

• Connect a phase sensor to lines 1L1, 1L2 and 1L3 on the main switch.
SM1GB0HA
Chapter 4.13 - 2 0115TW
• Switch on the supply voltage (low voltage distribution).
• The phase sensor should now indicate a right-hand (clockwise) field.

• Switch off the supply voltage (low voltage distribution) if the direction of rotation is not
correct and exchange two phases of the power connections 1L1, 1L2, and 1L3 of the
mains lead in the switch cabinet.
• Close the switch cabinet.
Finally start the hydraulic pump(s) in "Setting mode" and allow to run for a few seconds without
load in order to lubricate the hydraulic pump(s).
SM1GB0HA
0115TW Chapter 4.13 - 3
SM1GB0HA
Chapter 4.13 - 4 0115TW
5 Mould mounting
5.1 Preparation
If the machine has a robot interface and the machine is to be run without the robot, then the
latter should be switched off and the supplied dummy plug must be inserted. Operation of the
machine without this linking out is not possible. The installation of the links is detailed under
"Interfaces".
It is a good idea to check the following before mounting a mould, to avoid unnecessary work:
• Mould height and dimensions must suit the machine.
• The sprue bush or hot runner radius must correspond to the machine nozzle radius.
• The centring flange must correspond to the centre bore in the nozzle and clamping
platen.
• The length of the ejector bar and the ejector stroke must be compared with the machine
specification (see chapter "Technical Data").
• Check that the water fittings are the right size.
• The mould should have been checked for binding, seizing, missing or loose parts and
badly adjusted slide valves.
• Water and air connections should be made to check for leakage.
5.2 Mould mounting

1 Switch on main switch.
2 Press and release the emergency stop buttons on the machine and robot, if present; the
"Test emergency stop" error message will disappear
3 Turn on water supply to oil cooler
4 Check the safety device as described in the "Checking safety devices" paragraph.
5 Open and close all safety gates once (to test the safety gate
monitoring).
Press the "Open safety gate" and "Close safety gate" keys in case of a power-
operated safety gate (option).
6 The hydraulic drive and at the same time the oil pre-heating are switched on with the
"Drive On" key
SM1GB0IA
Chapter 5 - 1
0115TW
7 After the control boots up the "Start page" screen page will appear.
8 Press the "Alarms" menu key; a list of the active error messages will be displayed,
including the "Oil heating - Tolerance" error message.
This error message disappears automatically as soon as the hydraulic oil comes up to
operating temperature.
See also the "Interrupt list" chapter in the " UNILOG B6 User manual".
9 An activation of the key symbol opens the window for "System password".
10 For the log on to the control refer to chapter A 7 in the control unit’s manual.
If further error messages are displayed, see the "UNILOG B6 User manual", "Interrupt list"
chapter to find out how to clear them. Once all the errors are cleared and the drive is started,
mould mounting can be continued.
11 Clamping the mould on the nozzle platen

11.1 Press the "Mould open" key and open the clamping platen.
11.2 Press the "Setting mode" key; this avoids damaging the mould on initial opening.
SM1GB0IA
The mould may only be mounted by an authorised skilled technician!
The lifting equipment must at least correspond to the weight of the mould. For details
please refer to the manufacturer of the mould!
11.3 The mould halves must be prevented from sliding apart.

11.4 The mould must hang horizontally from the lifting equipment.
Danger of death! It must be ensured that no persons stand or linger under the suspended
load!
11.5 Bring the mould into the open clamping unit.

11.6 Locate the mould in the nozzle platen’s centring hole.
11.7 Position the mould square to the machine’s lateral axis.
CAUTION
The number of mould clamps must be adapted to the mould weight and the opening
force of the machine!
11.8 Clamp the mould to the nozzle platen with mould clamps; it is essential to use bolts of the
correct length; at least 1.5 D (= diameters of thread) must screw into the machine platen.
SM1GB0IA
Chapter 5 - 3
0115TW
The mould clamps (mounting elements for the mould; not supplied as standard with the
machine) must be the same height as the thickness of the mould mounting platen, as
otherwise there is a risk of the mould slipping.
If necessary use proper washers.
The above points apply equally to the mounting of a mould to mounting platens with
T-slots.
11.9 Press the "Mould Close" key and close the clamping platen.
11.10 For adjusting the zero points of the mould "Zeroising Clamping unit" refer to the chapter
"Machine in general / Zeroising".
12 Clamping the mould to the clamping platen

12.2 Clamp the mould to the clamping platen with mould clamps; make sure the screws are
the correct length; see step 11.8.
The lifting equipment should not be removed until the mould is bolted securely to both
platens and this has been verified by an authorised technician!
12.3 Remove lifting gear from mould, mount the safety strap holding the two mould halves
together, connect the ejector coupling (mould / hydraulic ejector cylinder).
12.4 Press the "Mould open" key and open the clamping platen.
SM1GB0IA
13 Set clamping force
13.1 Press the "Manual operation" key.
13.2 Press the "Clamping unit" menu key.

The "Clamping unit" page appears.
13.3 If the input field "Clamping force" is pressed, the "Numpad" appears. Here, the wished
clamping force can be entered in "kN" (shtn) (see also User manual A5).
13.4 Press "Mould open" key and crack the clamping platen open.
CAUTION
If the machine is to stand idle for an extended period of time, press the "Setting mode"
key and close the mould, continue to press the "Close mould" key (rinsing program of
the clamping side is activated automatically).
13.5 Press the "Mould Close" key and close the clamping platen.
SM1GB0IA
Chapter 5 - 5
0115TW
14 Log off from the control
CAUTION
To prevent set value entries by unauthorised persons, the user must log off after
finishing setting!
14.1 An activation of the key symbol opens the window for "System password".
If you want to interrupt or finish your work at the control unit, you will have to logout first.
This procedure prevents unauthorised input at the control unit.

14.2 Select the "Logout" key.
If the logout is successful, the window is automatically closed. As an acknowledgement,
user level 90 is displayed in the "User level symbol".
15 Connect the cavity pressure measuring (option) and temperature sensors.
CAUTION
The cables must be laid and installed as not to be damaged by the mould or the machine.
16 Connect the mould heating and cooling.
CAUTION
Please note the correct passage direction since the cooling may otherwise be subject to
negative influences.
The lines and cables must be laid and installed as not to be damaged by the mould or the
machine.
SM1GB0IA
5.3 Quick-action mould mounting system
Use the "Mouldfix" quick-action mould mounting system (option) to enable quick installation and
dismantling while the injection mould will automatically be levelled.
It may either be levelled horizontally or vertically depending on whether the injection moulds are
to be installed laterally using a rolling truck or from above using a crane.
Mould mounting
1 Switch on the machine as described in "Mould mouting", steps 1 to 10 (paragraph 5.2).
2 Press the "Setting mode" key.
3 Move clamping platen fully back.
4 Move injection unit fully back.

Only then may the wedge clamping elements of the "Mouldfix" be moved out (released).
5 Switch on key-operated "Mouldfix" switch (Position 1).
6 Move out (release) the wedge clamping elements of the "Mouldfix" for the
nozzle and the clamping platen until reaching the "Wedge clamping elements
released" limit switches. If the limit switches have not been reached the
movements of the clamping platen will be disabled.
7 The mould parts must be prevented from sliding apart.

8 Move the mould with the adapter platen of the nozzle unit into the nozzle platen’s
"Mouldfix" until reaching the limit stop.
SM1GB0IA
Chapter 5 - 7
0115TW
9 Clamp the nozzle side part of the mould to the nozzle platen by activating the wedge
clamping elements of the "Mouldfix" for the nozzle platen until reaching the "Wedge
clamping elements released" limit switches. If the limit switches have not been reached
the movements of the clamping platen will be disabled.
10 Move the clamping platen slowly forward until the mould is closed and the clamping unit’s
entire adapter platen fits to the clamping platen.
11 Clamp the clamping unit’s part of the injection mould to the clamping platen by activating
the wedge clamping elements of the "Mouldfix" for the clamping platen until reaching the
"Wedge clamping elements released" limit switches. If the limit switches have not been
reached the closing movement will be disabled.
12 Remove the safety devices for the preventing the injection mould from collapsing.
13 Switch off key-operated "Mouldfix" switch (Position 0).
Remove the key to protect the mould and prevent unauthorised reconnection.
To dismantle the injection mould proceed in reversed order.
The self-locking function of the wedge clamping elements prevents any part of the injection
mould - even if the hydraulic pressure drops to zero - from disengaging automatically from the
mould mounting platen.
SM1GB0IA
5.4 Magnetic quick-action mould mounting system
The magnetic quick-action mould mounting system (option) is another option for quickly
mounting or dismantling the mould.
Use eccentric rings to centre the injection mould in the clamping and nozzle platen. At the same
time the centering rings are to support the mould if the magnetic retention force is exceeded
when opening the mould.
Before mounting the mould the enclosed separate operating manual must be read. It contains
information on safety equipment, requirements on the mould, mould mounting, commissioning,
set value entries and maintenance.
Mould mounting
1 Prepare the mould according to the operating instructions for the magnetic quick-action
mould mounting system.
2 Switch on the machine as described in "Mould mouting", steps 1 to 10 (paragraph 5.2).
4 Move clamping platen fully back.
5 Move injection unit fully back.
6 Check the contact surfaces of the magnetic contact surfaces and the mould for dents and
eliminate them, clean them thoroughly and spray them with corrosion inhibitor.
7 Check whether magnetic modules have been demagnetised.
SM1GB0IA
Chapter 5 - 9
0115TW
8 Centre mould on the nozzle platen as described in steps 12.2 to 12.6 (paragraph 5,2
Mould mounting).
Magnetic field hazard. The magnetic field will almost close completely in the base plate
of the mould (in a depth of 12 mm / 0.47 inch). However, when in immediate proximity, it
may influence sensitive devices such as cardiac pacemakers, hearing aids, disks, etc.!
CAUTION
The power of the magnetic modules amounts to up to 16 kg / cm2 (5,58 lb / sq.in.).
During magnetising an object between the mould and the magnetic module will be
uncontrollably clamped and damaged!
9 Ensure that thereare no magnetisable objects (e.g. spanners) within the clamping unit
area.
10 Magnetise the nozzle unit’s magnet mounting plate.
11 Check the clamping procedure; the respective pilot lamp must light up on the control
panel or the manual operation unit.
12 Remove lifting gear from mould.
13 Press the "Mould Close" key and close the clamping platen.
14 Magnetise the clamping unit‘s magnet mounting platen.

15 Check the clamping procedure; the green pilot lamp must light up on the control panel or
the manual operation unit.
16 Remove the safety strap holding the two mould halves together.
SM1GB0IA
5.5 Interfaces
The interfaces and sockets for the peripheral equipment (option) are located on the rear side of
the machine.
Details of installation, connection and commissioning are to be found in the appropriate
Operating Manuals.
Before operating the machine with peripheral equipment, it is essential that the safety
regulations and operating manual of these devices are followed!
Electrical installation may only be carried out by a qualified electrician!
For some peripheral equipment a dummy plug must be used in the interface when the machine
is operated without the peripheral equipment.
See also the appropriate wiring diagrams in "Spare parts / plans" chapter.
Before switching on the emergency stop buttons should be released by rotating a quarter turn
clockwise and program selection switches set to the required position.
The start impulse for automatic operation of a peripheral device is given by starting an
automatic cycle of the machine.
Automatic operation is ended by operating an emergency stop button or by switching off or
changing the automatic cycle of the machine.
5.6 Checking the safety devices

The safety devices can only fulfil their purpose if their faultless operation can be guaranteed.
Therefore it is necessary to check the following for effective function before operation:
The function test for the safety device may only be carried out by a trained and skilled
technician!
• Electrical closing interlock: Proper function and securely fixed limit switches.
• Hydraulic interlock: Proper function and securely fixed limit switch.
• Mechanical scotch (option): Proper function and free movement of swinging scotch (flag)
on the clamping platen and the correct position (teeth) of the scotch bar.
SM1GB0IA
Chapter 5 - 11
0115TW
If a fault appears on the machine which causes the mechanical scotch to come into
operation, Battenfeld Customer Service or the responsible agent must be contacted.
• Purge guard: Proper function, free movement and securely fixed limit switches.
• Purge guard, safety gate and guarding: Security of all fixing bolts and undamaged
condition and proper function.
5.7 Test run and interlock test
Operating and other personnel may only stand in front of the machine on the operator’s
side during operation!
It is forbidden to stand on the machine or to reach into the injection unit during
operation!
Install required safety devices. The safety regulations in the chapter "Safety" are to be
followed without fail!
• After electrical installation safety devices are to be tested.

• Check hydraulic lines and components for leaks.
• Check all visible fittings for security.
• Close safety gates and check for proper fitting.
• Clear inside of the machine of all foreign bodies (forgotten mould).
• Set peripheral equipment to the starting position, i.e. the position in which no damage to it
or to machine components is possible.
• Turn on water supply to oil cooler
• Check function of safety devices.
CAUTION
It is essential to select "Setting" mode, or else the test run may damage the mould!
Check the movements of the various units as follows:

• Switch on main switch (to "1").
• Check the safety device as described in the "Checking safety devices" paragraph.
SM1GB0IA
• Open and close the clamping unit’s safety gate (to check the safety
gate monitoring).
Press the "Open safety gate" and "Close safety gate" keys in case of a
power-operated safety gate (option) and open and close the safety
gates entirely.
• Switch on drive ("Drive On" key).
• Start the pump without load and run it for a few seconds to allow for adequate lubrication.
• Press the "Setting mode" key.
• Assuming that the mould has been left in the "Mould closed" position after mould
mounting, open it with the "Mould open" key.
The movements of the other units (ejector, screw and nozzle) can now be checked and
their functions tested.
SM1GB0IA
Chapter 5 - 13
0115TW
SM1GB0IA
6 Structure and function
6.1 6.3 6.7 6.6 6.2
6.1 Clamping unit

6.2 Injection unit
6.3 Hydraulic
6.4 Pneumatics (option)
6.5 Airmould (Option)
6.6 Electric system - main switch cabinet
6.7 Control
SM1GB0JA
Chapter 6 - 1
0115TW
SM1GB0JA
6.1 Clamping unit
2 4 1 3
5
9 6
1 Clamping platen
2 Ejector
3 Nozzle platen
4 Thrust pin
5 Clamping cylinders
6 Quick-action cylinders
7 Tiebars
8 Suction pipe
9 Filling valve
SM1GB0KA
0115TW Chapter 6.1 - 1
6.1.1 Technical description
The clamping unit can be considered as an independent assembly attached to the machine
frame by bolts in the nozzle platen.
To allow unrestricted extension of the tiebars, the end platen is flexibly linked to the machine
frame.
The clamping force is established by means of the clamping cylinder which is formed as plunger
piston.
The clamping force is established by means of an arranged clamping cylinder and transferred to
the clamping platen via thrust pins.
Clamping and opening is carried out via two symmetrically arranged double-acting and quick-
acting cylinders.
The moveable clamping platen is guided on the machine frame by the clamping platen support.
The standard clamping platen supports consist of linear guide elements which transfer the
weight into the machine body. They are preadjusted in the factory and require no further
adjustments.
The hydraulic ejector is built into the clamping platen in the form of a double-acting hydraulic
cylinder.
6.1.2 Mechanical scotch

The mechanical scotch (option) prevents the closing movement of the moving platen when the
safety gate is open.
CAUTION
The mechanical scotch is an accident prevention device. It can only be effective if all
components are in perfect condition and the moving parts operate freely. Care must
be taken that the face of the scotch (or "flag"), against which a tooth of the scotch-bar
presses when it is activated, shows no significant wear. By replacing the scotch in time,
malfunctions of the mechanic safety device to prevent closing can be prevented!
SM1GB0KA
Chapter 6.1 - 2 0115TW
6.2 Injection unit
6.2.1 Technical description
1
5
The main components of the injection unit (or carriage) are the screw barrel (1), the nozzle
contact cylinder (2), the injection cylinder (3), the drive and bearings (4), hydraulic motor (5), the
material hopper and the support.
Low maintenance linear bearings enable precise axial movements of the injection unit.
The mechanical stop prevents any movements out of the linear bearings when dismantling the
screw.
The two nozzle contact cylinders are designed as double-acting hydraulic cylinders. The piston
rods are designed as guide rails and are attached to the nozzle platen. The nozzle contact
cylinders have a long stroke so that the nozzle is easily accessible when the carriage is moved
right back.
A stroke transducer, on the rear side of the machine, records the movements of the nozzle
contact cylinders and transfers them to the machine control.
The screw is driven directly by a low speed hydraulic motor. This minimises the rotating masses.
The torque of the hydraulic motor is suited to the load at any time.
SM1GB0LA
A proximity switch records the screw speed and transfers it to the control. A stroke transducer,
on the rear side of the machine, records the stroke of the screw and transfers it to the machine
control.
The injection unit ensures a high plasticising rate, achieved partly by an optimised L/D (= length
/ diameter) ratio. The barrel and the nozzle are equipped with ceramic heater bands. Different
heat outputs and zones can be obtained by arranging of several heater bands side by side.
ATTENTION
To ensure a long service life for the screw barrel heater bands, they should be checked
for secure fitting when hot at regular intervals, starting with commissioning!
Depending on the moulding compound to be processed, the heating of the screw barrel is
additionally equipped with an outside cooling (option) by means of radial fans or with a cooling
by means of heat transfer oil (option).
The material hopper which is used for receiving the moulding compound can be easily removed
by undoing one fixing bolt. The hopper outlet can be closed with a slide.
A magnet (option) in the material hopper is used for separating steel particles from the moulding
compound. This procedure is recommended especially when processing regranulated material.
Three continuously adjustable brackets allow adjusting the magnet to the desired distance to
the wall of the material hopper.
SM1GB0LA
6.2.2 Screw drive
Before checking, the machine must be switched off at the main switch and must be
secured against accidental reconnection!
The axial bearing of the injection unit is arranged so that the leakage line from the hydraulic
motor lubricates it. No maintenance is thus necessary in this case.
With the servomotor option, the oil level must be checked before the first start-up and, if
necessary, oil must be filled or refilled.
For the demands on the lubricant refer to the paragraph "Hydraulic oil and lubricants".Care must
be taken to only use gear oils having the same specification.
For the check and oil change intervals, please refer to the "Maintenance" chapter.
SM1GB0LA
6.2.3 Adjusting the nozzle centre
Injection unit up to size 1330
Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate
personal protective equipment!
1 Measure the centricity of the nozzle with a caliper gauge by measuring the distance from
the nozzle bore to the opening in the platen at several places - at least four. The tolerance
must not exceed 0.2 mm (0.008 inch).
2 Use the 3 set screws (1) after unscrewing the locking nuts (2) to move the screw barrel
into the required position. In this process, always unscrew the "opposite" set screws and
tighten after the adjustment to avoid twisting the screw barrel.
3 Retighten locking nut (2) and set screws (1).
4 Then carry out another measurement for test purposes.
SM1GB0LA
6.2.4 Basic requirement for changing the nozzle
1 Press the "Manual operation" key.
2 Set peripheral equipment (option) to the starting position and switch off any peripheral
equipment according to its operating manual.
3 Switch off material feeder (option).
() Only for Airmould® nozzle: Shut off the nitrogen supply to the Airmould® pressure
generation unit.
If appropriate, switch off the Airmould® nitrogen generation unit according to the separate
operating instructions.
Switch off the Airmould® pressure generation unit according to the separate operating
manual.
If components of the machine are located higher than the average body height, climbing
aids and working platforms which meet the legal safety requirements must be used for
installation, dismantling, modification, operation, and maintenance!
Do not use components of the machine as climbing aid. When working at greater heights
to proper equipment for protection against falling down must be worn!
4 Move the climbing aid in front of the machine.

5 Move the "Material hopper" away from the "Screw Barrel" feed zone.
6 Move the "Core pullers" (option) out of the mould. "Move out core puller" means that the
moulding is removed from the mould or ejected by the "Ejector" if the "Core puller" has
been moved into this position.
7 Move the "Clamping platen" to the starting position (mould open).
8 If necessary remove the moulding(s) from the mould using the "Ejector".
SM1GB0LA
9 Heat the "Screw barrel" heating to the operating temperature that was set last.
10 Press the "Injection unit back" key until there is enough room to purge the remaining
moulding compound.
11 Open the "Protective guard” of the "Nozzle”.

12 Place a suitable container in front of the "Nozzle".
Risk of injury from pinching or crushing hazard between the purge guard and the
nozzle platen when closing the purge guard!
13 Close the "Protective guard" of the "Nozzle".

14 Eject the residual moulding compound at short intervals.
15 Purge the screw barrel with an appropriate cleaning material.
Consult your plastics manufacturer about the suitable material.
16 Switch off water system, pneumatic system, modular Airmould system (option). See also
the paragraph "Shutting down the machine" (chapter "Operation").
17 Press the "Injection unit back" key until there is enough space to remove the "Nozzle".
Only for Airmould® nozzle:

If the nitrogen system is not relieved from pressure before starting work, it may lead to
an explosive loss of pressure with risks of damage and injury!
For Airmould® nozzle:

() Relieve the "Modular Airmould® system" from pressure. For the procedure see the
operating manual "Modular Airmould® system" (chapter "Transport - installation",
paragraph "Preparation for no-load mode and interlock test without material").
() Switch off the main switch at the "Modular Airmould® system" and secure against
unintentional reconnection.
SM1GB0LA
18 Switch off the heating of "Nozzle" and "Screw barrel".
19 Switch off hydraulics ("Hydraulics stop" key).
20 Switch off the main switch and use a padlock to prevent accidental reconnection. The
main switch should be operated whenever possible without applied load.
21 Open the "Protective guard" of the "Nozzle".
The nozzle may only be dismantled and mounted by an authorised skilled technician!
ATTENTION
Only use tools and support equipment that will not damage the assembly components!
The remaining procedure is described in the following chapters depending on the nozzle type
SM1GB0LA
6.2.4.1 Changing "open” nozzles
Figure 1 Open nozzle
Figure 2 Open Airmould® nozzle, pressure-controlled
Basic requirement paragraph 1-20 (chapter 6.2.3.1)
1 Dismantle the heater band of the "Nozzle" (1).

2 Position a hexagon spanner on the "Hexagon" (3) and unscrew the "Nozzle" (2).
Unscrew the "Union nut" (B) of the "Nitrogen pressure line" (A) at the "Nozzle body".
3 Position a hexagon spanner on the "Hexagon" and unscrew the "Nozzle body".
Fire hazard! Use no flammable solvents!
4 Thoroughly clean the "Nozzle" and the "Nozzle body". Use wire brush or brass brush.
Thoroughly remove old grease residues in the thread gaps.
Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of
the mechanial and technological characteristics of the components.
The components can also be cleaned in an ultrasonic cleaning reactor or a fluidized bed
bath. We also recommend the use of a blast system with thermoset particles.
Danger of injury and damaging components! Only components that were either supplied
or specified by Battenfeld should be implemented!
SM1GB0LA
ATTENTION
Do not use any oily lubricants which may evaporate!
5 Lubricate the thread of the new or cleaned "Nozzle" with a high-capacity assembly paste.
It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at
least up to 350 °C / 662 °F).
Check the contact surfaces for damage and wear before mounting.
When fitting a new "Nozzle" it should be first verified that the "Nozzle radius" is correct for
the sprue bush (whose radius should be slightly larger than that of the "Nozzle").
6 Screw the "Nozzle body" home by hand but do not finally tighten.
7 Screw the "Nozzle" home by hand but do not finally tighten.
8 Mount the heater band of the "Nozzle".
10 Switch on hydraulics ("Hydraulics Start" key).
11Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature.
The operator must without fail ensure proper assembly of the nozzle to prevent risk of its
flying out!
12 Tightly screw in the "Nozzle” and "Nozzle body” after heating to operating temperature.
Torque settings see chapter "Technical data”.
Screw in the "Union nut" of the "Nitrogen pressure line" at the "Nozzle body" until there is
a significant increase in force detectable.
13 Close the "Protective guard” of the "Nozzle”.

Switch on the main switch at the control cabinet of the "Modular Airmould® system".
Pressurize the "Nitrogen pressure line" and check the "Union nut" for leaks. For
the procedure see the operating instructions "Modular Airmould® system" (chapter
"Maintenance") paragraph "Nitrogen leakages".
SM1GB0LA
6.2.4.2 Nozzle changing
Working data Shut-off nozzles
System
max. injection flow Nozzle contact Back Injection Tempera-
pressure Lever length/
Activation (ccm/sec./cinch/ force max. (kN/ pressure pressure max. ture max.
pneum./hydr. stroke (mm/inch)
sec.) (PS) sh ton) (bar/psi) (bar/psi) (°C/°F)
(bar/psi)
Herzog Typ SHP Spring 290 / 4200
Herzog Typ HP0 pneum./integrated 500 / 7250

500 / 30,50 70 / 7,87 6,0 / 87
Herzog Typ HP0 pneum./external 500 / 7250 77/3,03 // 17/0,7
Herzog Typ HP0 hydr./external 500 / 7250 40 / 580 77/3,03 // 17/0,7
Herzog Typ HP1 pneum./integrated 150 / 2175 6,0 / 87,0
Herzog Typ HP1 pneum./external 150 / 2175 4,0 / 58 77/3,03 // 12/0,5
Herzog Typ HP1 pneum./external 1600 / 97,63 130 / 14,61 250 / 3625 3000 / 43511 400 / 752 4,0 / 58 116/4,56 // 22/0,9
Herzog Typ HP2 pneum./integrated 250 / 3625 6,0 / 87,0

3500 / 213,57 180 / 20,23
Herzog Typ BHP0 pneum./integrated 1600 / 97,63 130 / 14,61 200 / 2900 6,0 / 87,0
Herzog Typ BHP1 pneum./integrated 500 / 30,50 46 / 5,17 200 / 2900 6,0 / 87,0
ENG Typ L20 pneum./integrated 1000 / 61 100 / 11,24

600 / 8700 3000 / 43511 400 / 752 6,0 / 752
ENG Typ L30 pneum./integrated 3500 / 213,57 130 / 14,61
PSG Typ G30 Spring 250 / 3625
PSG Typ G30 pneum./external 200 / 12,2 90 / 10,1 250 / 3625 4,0 / 58 35/1,38 // 8/0,31
PSG Typ G30 hydr./external 350 / 5076 30 / 435 35/1,38 // 8/0,31
PSG Typ G48 pneum./external 250 / 3625 6,0 / 87,0 35/1,38 // 5/0,20
3000 / 43511 400 / 752
PSG Typ G48 pneum./external 500 / 30,50 100 / 11,24 250 / 3625 6,0 / 87,0 60/2,36 // 8/0,32

1600 / 97,63 130 / 14,61
PSG Typ G70 pneum./external 350 / 5076 6,0 / 87,0 90/3,52 // 10/0,40
Working data Shut-off nozzles

Setting instructions of the external shut-off cylinder pneumatic / hydraulic:
Nozzle closed:
Needle contacts the nozzle point, piston in the shut-off cylinder in floating position - minimum
distance to unit > 1mm
Nozzle open - Herzog system:

Needle shoulder contacts nozzle body, lever is retracted from the needle, however, does not
touch the basic body, piston of the shut-off cylinder in limit position on unit
Nozzle open - Fuchslocher system:

Needle with cross yoke contacts nozzle body, lever will rollers is retracted from the cross yoke >
1 mm, piston of the shut-off cylinder in limit position on unit
Guide values of the lever strokes - setting stroke of shut-off cylinder - see table
SM1GB0LA
Chapter 6.2 - 10 0115TW
6.2.4.2.1 Replacing the "Herzog" needle shut-off nozzle of type SHP,
spring-controlled
6
1 5
10
3
2
9
7
1 Body
2 Needle guide bush
3 Fixing pin
4 Thrust ring
5 Spring assembly
6 Adaptor
7 Shut-off needle
8 Nozzle head
9 Heater band
10 Temperature probe
SM1GB0LA
0115TW Chapter 6.2 - 11
1 If necessary, unscrew "Temperature probe" (10)

2 Dismantle the heater band of the nozzle (9)
3 Screw out the nozzle head (8)
4 Withdraw the shut-off needle (7)
5 Screw off the "Adaptor" (6)
6 Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass
brush.
ATTENTION
Do not grease components coming into contact with the melt!
7 Greasing these components will cause impurities to the melt.

Lubricate all threads of the new or cleaned "Needle valve nozzle" with a high-capacity
assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-
resistent (at least up to 350 °C / 662 °F).
Check the contact surfaces for damage and the individual components for wear and
function before mounting.
SM1GB0LA
Chapter 6.2 - 12 0115TW
8 Mount the needle valve nozzle in reverse order
9 Screw the adaptor (6) home by hand but do not finally tighten
10 Insert the shut-off needle (7)
11 Screw the nozzle head (8) home by hand but do not finally tighten
12 Mount the heater band (9) of the nozzle
13 If necessary, screw the temperature probe (10) home by hand but do not finally tighten
16 Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature.
flying out!
17 Tightly screw in the adaptor / head / temperature probe after heating to operating
temperature.
Tightening torque: "Nozzle head" (8) - 220 Nm (162 ft lb).
"Fixing pin" (3) - 3 Nm (2 ft lb).
"Body " (1) - 170 Nm (125 ft lb).
"Adaptor" (7) - see the "Technical Data" chapter.
SM1GB0LA
0115TW Chapter 6.2 - 13
6.2.4.2.2 Changing the "Fuchslocher” needle valve nozzle
3 1
2
6 5
4
1 Nozzle body
2 Spring chamber
3 Compression spring
4 Heater band
5 Shut-off needle
6 Nozzle head
1 Screw out the temperature probe

2 Dismantle the heater band (4 from the nozzle head (6).
3 Position a hexagon spanner on the "Hexagon" and unscrew the nozzle body (1).
The "Spring chamber" (2) must not be dismantled. We can accept no responsibility for
damage resulting from improper handling!
If the needle valve nozzle does not function any more, please contact our Customer Service.
The addresses can be found in the "Customer service" chapter.
SM1GB0LA
Chapter 6.2 - 14 0115TW
brush.
ATTENTION

Lubricate all thread of the new or cleaned "Needle valve nozzle" with a high-capacity
6 Screw the nozzle body (1) home by hand but do not finally tighten.
7 Mount the heater band (4) of the "Nozzle".
8 Screw in the temperature probe.
11Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature.
SM1GB0LA
0115TW Chapter 6.2 - 15
flying out!
12 Tightly screw in the "Nozzle" and "Nozzle body" after heating to operating temperature.
Torque setting: Nozzle head (6) - 300 to 350 Nm (221 to 258 ft lb).
Nozzle body (1) - 350 to 400 Nm (258 to 295 ft lb).
SM1GB0LA
Chapter 6.2 - 16 0115TW
6.2.4.2.3 Replacing the pneumatically or hydraulically triggered
"Herzog" needle valve nozzle, type HP, with integrated
control cylinder
10 9
3
4 11
5
1 Nozzle head
2 Shut-off needle
3 Fixing pin
4 Lever bolt
5 Lever
6 Screws
7 heater band
8 Temperature probe
9 Adaptor
10 Yoke / adaptor ring
11 Control cylinder
SM1GB0LA
0115TW Chapter 6.2 - 17
1 If necessary, unscrew temperature probe (8).

2 Dismantle the heater band (7) of the nozzle.
3 Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from
the control cylinder (11) and remove the lever (5).
4 Screw out the nozzle head (1).
5 Withdraw the shut-off needle (2).
6 Screw off the adaptor (9).
brush.
ATTENTION

SM1GB0LA
Chapter 6.2 - 18 0115TW
9 Mount the needle valve nozzle in reverse order.
10 Screw the adaptor (9) home by hand but do not finally tighten.
11 Insert the shut-off needle (2).
12 Screw the nozzle head (1) home by hand but do not finally tighten.
13 Mount the heater band (7) of the nozzle.
14 If necessary, screw the temperature probe (8) home by hand but do not finally tighten.
15 If the control cylinder (11) did not reach the wished position after having screwed it in (e.g.
control cylinder (11) faxing vertically up), the 12 screws (6) must be screwed out by 4
turns and then the position of the control cylinder (11) can be changed clockwise.
16 Tighten 2 screws (6) crosswise, check the gap between body and adaptor ring up to a
Turn clockwise
maximum of 2.5 mm (0.1 inch)
SM1GB0LA
0115TW Chapter 6.2 - 19
17 Tighten all screws crosswise
Torque HP0 HP1 HP2
1st step Prefixing Prefixing Prefixing

2nd step 7 Nm 15 Nm 35 Nm
3rd step 10 Nm 22 Nm 45 Nm
4th step 12 Nm 25 Nm 50 Nm
18 Connect pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the
control cylinder (12) and mount the lever (5).
flying out!
temperature.
Tightening torque:
Designation Torque
HP0 HP1 HP2
Screws 12 Nm (9 ft lb) 25 Nm (18 ft lb) 50 Nm (37 ft lb)
Head 220 Nm (162 ft lb) 500 Nm (369 ft lb) 1200 Nm (885 ft lb)
Heater band screws by hand by hand by hand
Temperature probe by hand by hand by hand
SM1GB0LA
Chapter 6.2 - 20 0115TW
6.2.4.2.4 Replacing the pneumatically triggered "Herzog” bolt valve
nozzle, type HP, with integrated control cylinder
9
8
7
11
6
12
2
10
4 3
1 Nozzle head
2 Bolt lock
3 Lever bolt
4 Lever
5 Screws
6 Heater band
7 Temperature probe
8 Adaptor
9 Yoke / adaptor ring
10 Control cylinder
11 Shut-off nut
12 Body
SM1GB0LA
0115TW Chapter 6.2 - 21

3 Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from
the control cylinder (10) and remove the lever (4).
6 Screw out the shut-off nut (11).
7 Remove the bolt lock (2).
Sometimes, the removal of bolt and bolt bushing might be a problem Do not exercise too
much force on this part. If you have problems during removal, please contact the Herzog
company.
Use a mandrel to carefully knock up the bolt. Remove bushing and bolt from above.
The grooves on the bolt bushing must be aligned on the body by means of the positioning pin.
SM1GB0LA
Chapter 6.2 - 22 0115TW
8 Thoroughly clean the components of the "Nozzle". Use wire brush or brass brush.
ATTENTION

10 Mount the bolte valve nozzle in reverse order.
12 Push in the bolt lock (2) and screw in the shut-off nut (11).
16 Connect pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the
control cylinder (10).
18Switch on hydraulics ("Hydraulics Start" key).
SM1GB0LA
0115TW Chapter 6.2 - 23
flying out!
temperature.
Tightening torque: Shut-off nut (11) - 180 Nm (133 ft lb).
Screws (5) - 25 Nm (18 ft lb).
Bolt screws (11) - 30 Nm (22 ft lb).
Nozzle head (1) - 150 Nm (111 ft lb).
21 Close the "Protective guard” of the "Nozzle”.
SM1GB0LA
Chapter 6.2 - 24 0115TW
"Herzog" needle valve nozzle, type HP
1 Adaptor
2 Temperature probe
3 Heater band
4 Nozzle head
5 Screws
6 Rod assembly

2 Dismantle the rod assembly (6).
5 Withdraw the shut-off needle.
SM1GB0LA
0115TW Chapter 6.2 - 25
brush.
ATTENTION

12 Screw the head (1) home by hand but do not finally tighten.
SM1GB0LA
Chapter 6.2 - 26 0115TW
flying out!
temperature.
Tightening torque:
Designation Torque
HP0 HP1 HP2
Screws 12 Nm (9 ft lb) 25 Nm (18 ft lb) 50 Nm (37 ft lb)
Head 220 Nm (162 ft lb) 500 Nm (369 ft lb) 1200 Nm (885 ft lb)
Heater band screws by hand by hand by hand
Temperature probe by hand by hand by hand
19 Assemble the rod assembly (6).

SM1GB0LA
0115TW Chapter 6.2 - 27
The nozzle is delivered as sub-assemblies. The final assembly is made on the machine
After having aligned the rod assembly with the nozzle, the flange bolts can be tightened
crosswise in four steps. The gap between body and adaptor ring can change between 0.5
and2.5 mm (0.02 and 0.1 inch).
Gap between body and adaptor ring
Flange bolts
Rod assembly
Tighten the screws crosswise

Step 1 = prefix all screws evenly
Step 2 = 70 % of the tightening torque
Step 3 = 90 % of the tightening torque
Step 4 = tighten with 12 Nm (9 ft lb)
SM1GB0LA
Chapter 6.2 - 28 0115TW
"Fuchslocher" needle valve nozzle
1
2
1 Nozzle body
2 Thrust ring
3 Heater band
4 Nozzle head
5 Shut-off needle
6 Fork
1 If necessary, unscrew temperature probe.

2 Dismantle the heater band (3).
3 Dismantle the rod assembly from the fork (6).
5 Withdraw the shut-off needle (5).
6 Screw out the nozzle body (1).
SM1GB0LA
0115TW Chapter 6.2 - 29
brush.
ATTENTION

14 If necessary, screw the temperature probe home by hand but do not finally tighten.
SM1GB0LA
Chapter 6.2 - 30 0115TW
flying out!
temperature.
SM1GB0LA
0115TW Chapter 6.2 - 31
6.2.4.2.7 ENG pneumatic needle valve nozzle with integrated control
cylinder
5 6
1 Nozzle body
2 Control cylinder
3 Rod assembly
4 Nozzle head
5 Body
6 Tension nut
1 If necessary, unscrew temperature probe.

2 Dismantle the heater band.
3 Dismantle the rod assembly (3).
5 Withdraw the shut-off needle.
6 Screw out the nozzle body (1).
SM1GB0LA
Chapter 6.2 - 32 0115TW
brush.
ATTENTION

11 Insert the shut-off needle.
13 Mount the heater band of the nozzle.
14 If necessary, screw the temperature probe home by hand but do not finally tighten.
SM1GB0LA
0115TW Chapter 6.2 - 33
flying out!
temperature.
Tightening torque: "Tension nut" (6) L20 - 600 Nm (443 ft lb).
L30 - 1200 Nm (885 ft lb).
"Nozzle head” (4) L20 - 250 Nm (184 ft lb).
L30 - 600 Nm (443 ft lb).
SM1GB0LA
Chapter 6.2 - 34 0115TW
6.2.5 Dismantling the screw barrel / screw
6.2.5.1 Dismantling the screw up to size 750
1 Dismantle the "Nozzle" as described in the paragraph "Dismantling the nozzle".

2 Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical
stop.
3 Open the "Safety gate” on the operator and rear side.
4 Unscrew the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen".
5 Press the "Injection unit forward" key. The "Piston rods" of the "Nozzle contact cylinders"
are moved in.
SM1GB0LA
0115TW Chapter 6.2 - 35
8 Dismantle the cover of the "Guarding" of the "Injection cylinder".
ATTENTION
Only use tools and aids which do neither damage the nozzle nor its components
described below!
9 Slightly unscrew the "Screws" (1) of the "Clamping disc" (2) and remove the two
"Wedges" (3).
10 Slightly loosen but do not unscrew the "Clamping bolt".

11 Swivel out the "Injection unit" in the direction of the operator side.
12 Dismantle "Nozzle" and / or "Nozzle head" as described in this chapter.
SM1GB0LA
Chapter 6.2 - 36 0115TW
13 Secure the "Screw" with a corresponding aid and pull it out of the "Screw barrel" to the
front. For the weight of the "Screw", see the "Technical data" chapter.
14 If necessary, unscrew the "Screw tip" as described in this chapter.
Danger of injury and damaging components! Only parts (nozzle, screw, barrel and its
fixing screws) supplied or specified by Battenfeld may be used!
15 Clean the "Screw" and the "Screw tip" or mount a new "Screw" and "Screw tip".
- Coat all threads with a temperature resistant Molykote.
- Check the contact surfaces for damage and the individual components for wear and
The "Screw" is always mounted in reverse order as described in this chapter.
6.2.5.2 Dismantling the screw barrel up to size 750
1 Dismantle the "Screw" as described in this chapter.

2 Disconnect the heater band and temperature sensor of the "Screw barrel" at the
corresponding plug connection.
3 Disconnect the radial fans for the "Outside cooling of the screw barrel" (option) at the
corresponding plug connection.
4 Dismantle the "Guarding" of the "Screw barrel".
SM1GB0LA
0115TW Chapter 6.2 - 37
ATTENTION
The "Screw barrel" must not be placed on the "Heater bands" since they can be damaged
by its weight.
5 If no appropriate facility for placing the "Screw barrel" is available, the heater bands
and the radial fans for the "Outside cooling of the screw barrel" (option) have to be
dismantled.
6 Screw in the "Extension" (threaded rod) into the threaded borings in the "Screw barrel".
7 Screw the "Eye bolts" into the "Extension".
Danger of death! It must be ensured that no persons stand or linger beneath the suspended
barrel. For weights, see chapter "Technical data"!
The safe working load of the lifting gear must equal or exceed the weight of the screw
barrel!
Do not use nylon lifting slings. Lifting equipment must withstand the temperature of the
screw barrel!
8 Attach the lifting gear to the "Eye bolts" and take up the slack.
9 Unscrew "Bolt".
SM1GB0LA
Chapter 6.2 - 38 0115TW
10 Unscrew the "Locking ring". (Special tool: C-spanner according to DIN 1810)
11 Loosen the "Hexagon nuts" and slightly unscrew the "Screws".
12 Remove the "Screw barrel" forwards from its "Drive coupling". Make sure the lifting
equipment is also moved along slowly. For the weight of the "Screw barrel", see the
"Technical data" chapter.
13 Place the "Screw barrel" on a suitable facility. The "Screw barrel" must not be placed on
the "Heater bands" since they can be damaged by its weight!
SM1GB0LA
0115TW Chapter 6.2 - 39
Fitting
Before installing the "Screw barrel", the entire mating surface must be coated with a corrosion
inhibiting lubricant.
Coat all threads with a temperature resistant Molykote. Check the contact surfaces for damage
and the individual components for wear and function before mounting.
Danger of injury and damaging components! Only parts (nozzle, screw, barrel and its
fixing screws) supplied or specified by Battenfeld may be used!
The "Screw barrel" is then installed in reverse order.
ATTENTION
The torque settings for the "Bolts" are detailed in the chapter "Technical Data" and/or in
the spare parts list.
After fitting the centricity of the nozzle should be checked ("Transport - Installation" chapter).
6.2.5.3 Retooling for a different screw diameter up to size 750
Coat all threads with a high-capacity assembly paste. It must be water-repellent, corrosion-
proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F). Check the contact
surfaces for damage and the individual components for wear and function before mounting.
1 Dismantle "Screw" and "Screw barrel" as described in this chapter.

2 Cover the entire mating surface of the new "Screw barrel" with a "Heat-resistant
Molykote".
3 Mount the new "Screw barrel" as described in this chapter.
4 Mount the "Screw tip" as described in this chapter.
5 Insert the new "Screw" into the "Screw barrel" until the "Screw shaft" is located in front of
the "Thrust piece".
SM1GB0LA
Chapter 6.2 - 40 0115TW
6 With a "Screw" with a smaller diameter, mount the supplied "Sleeve" onto the "Screw
shaft" (push on).
7 Push the "Screw shaft" into the "Thrust piece" to the stop.
8 Adjust the "Screw shaft" so that the "Wedges" can engage in the cut.
9 Insert the new "Wedges" (3) into the recess of the "Thrust piece".
10 Screw the "Screws" (1) of the "Clamping disc" (2). The torque settings for the "Bolts" are
detailed in the chapter "Technical Data".
11 Mount the "Nozzle" as described in the pargraph "Dismantling the nozzle".

12 Label the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" in such a
manner that if is unmistakably assigned to the corresponding "Screw barrel".
SM1GB0LA
0115TW Chapter 6.2 - 41
13 Dismantle the "Extension" of the "Piston rod" of the "Nozzle contact cylinders".
14 Mount the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" for the current
"Screw barrel". The key surface (1) must be vertically positioned to ensure proper closing
and opening of the purge guard. The torque settings for the "Bolts" are detailed in the
chapter "Technical Data".
15 Fit the "Heater bands" hand-tight to the "Screw barrel" and mount the "Material hopper
feed throat" if necessary.
16 Displace the "Guarding" with the stroke measuring system of the "Nozzle". If the new
"Screw barrel" is larger than the old one, move the stroke measuring system to the right,
away from the "Nozzle platen".
17 Mount the "Nozzle" and / or "Nozzle head" as described in this chapter.

18 Swivel the "Injection unit" in towards the "Nozzle platen".
19 Screw in the "Clamping bolt". The torque settings for the "Bolts" are detailed in the
chapter "Technical Data".
20 Install the cover of the "Guarding" of the "Injection cylinder".
21 Prepare the machine as described in the "Operation" chapter in the paragraph "Test run
without material".
23 Press the "Injection unit back" key. The "Piston rods" of the "Nozzle contact cylinders" are
moved out.
24 Open the "Safety gate" on the operator and rear side.
SM1GB0LA
Chapter 6.2 - 42 0115TW
25 Scre in the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen".
26 Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical
stop.
27 Mount the "Nozzle" in reverse order as described in the paragraph "Dismantling the
nozzle".
28 Recalibrate the stroke measuring system of the "Nozzle" (see "User manual").
29 Check the nozzle centring as described in chapter "6.2.3 Levelling the machine".
6.2.5.4 Dismantling the screw tip
1 Dismantle "Nozzle" and / or "Nozzle head" as described in this chapter.

2 Dismantle the "Screw" as described in this chapter.
ATTENTION
Left hand thread! When removing or changing the screw tip it should be noted that the
screw tip is fitted to the screw with a left-hand thread!
3 Screw out the "Screw tip" using a special tool (option).

"Screw tip" with "Back flow check with ring".
SM1GB0LA
0115TW Chapter 6.2 - 43
"Screw tip" with "Back flow check with ring".
4 Thoroughly clean the components of the "Screw tip”. Use wire brush or brass brush.
ATTENTION

Lubricate all threads of the new or cleaned "Screw tip" with a high-capacity assembly
paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent
(at least up to 350 °C / 662 °F).
SM1GB0LA
Chapter 6.2 - 44 0115TW
6.2.6 Cleaning the barrel, material changes
The increasing requirements for quality finished plastic articles necessitate the frequent and
thorough cleaning of all components which come into contact with plastics.
6.2.7 Purging out with virgin polyethylene

This process ensures an almost total purging of the previous material. However the
polyethylene must in turn be forced out of the screw and barrel by the new material. It is not
usually necessary to clean the screw by hand.
6.2.8 Purging out with a barrel purging agent.

The purging compount is usually a colourless, high molecular weight, thermoplastic material
which at approx. 100 °C (212 °F) is viscoelastic, but does not flow, melt or stick. In the form of
an elastic plug, it pushes the previous material from the screw barrel. Usually, it is not necessary
to clean the screw by hand.
Before cleaning shut-off nozzles and open nozzles must be removed and the nozzle
temperature lowered. The temperature of the screw barrel should stay below (below 300 °C /
572 °F), injection pressure should be set to minimum or slightly above if required.
6.2.9 Cleaning the screw barrel
ATTENTION
The screw must never be cleaned with a gas burner, a sand blast system or by glowing
out!
These methods result in the loss of the mechanical and technological characteristics of the
screw. In such a case, all warranty claims expire.
The screw must be cleaned with a brass brush only. Using a wire brush can damage the
surface. We also recommend the use of a blast system with thermoset particles.
The barrel is cleaned with a rotating brass brush mounted to a long rod; a hand-held electric drill
or similar device can be used to drive it.
6.2.10 Storage
When storing the barrel it has been found effective to fill the barrel with about (200 g / 7 oz)
of silica gel or similar desiccant and seal the openings. The screws should be kept in plastic
sleeves, also containing silica gel. This will largely prevent corrosion.
SM1GB0LA
0115TW Chapter 6.2 - 45
SM1GB0LA
Chapter 6.2 - 46 0115TW
6.3 Hydraulics

The hydraulic system of the machine has a number of beneficial features:
• Easily accessible hydraulic system.
• Energy saving pump with electric adjustment enables smooth movements with high
precision and extremely short dry cycle times.
• The hydraulic components are arranged so that pipes and hoses are reduced to a
minimum.
• Maintenance-friendly construction.
• Full flow filtration keeps the oil quality high for long periods.
6.3.2 Pump unit

The pump assembly comprises a speed-controlled servo-motor, a pump carrier, a pump carrier
support, a damping component and the fixed displacement pump.
The pump assembly is located at the rear side of the machine in the clamping-side upright of
the base frame.
A compressed oil line connects the pump unit with the pump block. The vacuum oil line leads to
the oil tank.
There is no way of closing the line between hydraulic tank and pump unit (shut-off valve as an
option).
6.3.3 Hydraulic tank

The hydraulic tank is a fixed part of the machine frame and is equipped with a filler cap with
strainer, venting filters, and an oil level indicator with electrical monitoring and a temperature
sensor.
The oil tank may only be filled through the strainer of the filler cap. This can be found within the
machine frame close to the end platen.
The oil, of cleanliness class 17/15/12 acc. to ISO 4406 (Class 6 acc. to NAS 1638), must be
prefiltered through a mobile filtration unit fitted with a 3 μm mesh filter.
The hydraulic tank is equipped with connectors for an external oil filtration unit.
The hydraulic tank is cleaned via the front-side cleaning cover.
SM1GB0MA
6.3.4 Pressure filter
To improve the reliability and longevity of the hydraulic components and seals, a non-bypass
pressure filter (filter mesh 5 μm absolute) is provided in the main pressure line of the hydraulic
system. The pressure filter is flanged to the pump block.
The pressure filter has an electrical clogging monitor which sends a warning message to the
control screen if it is triggered.
If this message has not disappeared by the time the oil has reached its preheating temperature,
the filter element must be replaced at once.
CAUTION
To ensure trouble-free operation and long service life of the hydraulic components, only
original filter elements may be used!
6.3.5 Oil cooler

In the oil cooler, cooling water is directed through the cooling lines which are surrounded by
hydraulic oil, so that at the appropriate water flow rate and temperature adequate cooling of the
hydraulic oil can be ensured.
It is essential to ensure that the water used is maintained at the quality detailed in
"Maintenance" chapter. Otherwise a water filter (option) must be fitted in the supply to protect
the operation of the cooling water shutoff valve.
This regulates the cooling water flow and maintains a constant oil temperature by opening and
closing the water supply as appropriate.
6.3.6 Control and display

The oil temperature is measured in the oil tank. This temperature is indicated on the screen of
the machine control unit to the operating personnel.
SM1GB0MA
6.3.7 Pressure setting
The speed-controlled servo motor takes care of the hydraulic pressure setting for all functions.
The control is effected by entering the corresponding pressure for each function on the control
screen. Pressures are entered in "bar" (psi).
6.3.8 Speed setting

The servo motor takes care of the hydraulic speed setting for all functions.
The control is effected by entering the corresponding speed for each function on the control
screen. Speeds are entered as absolute values (mm/sec, inch/sec).
6.3.9 Hydraulic oil preheating

The oil temperature values depend on the oil viscosity used (HLP32/HLP46).
As soon as the hydraulic pump is started, the cold hydraulic oil is automatically preheated to a
temperature of bis das Hydrauliköl 40 °C (104 °F) HLP46 (HLP32 30 °C (86 °F)) .
While the oil temperature is below this value, the screen shows an error message and the
machine can not be moved. After reaching the 40 °C (104 °F) HLP46 (HLP32 30 °C (86 °F))
mark, the oil preheating switches off and the machine is ready for operation.
While the IMM is running, the oil temperature is regulated to a constant 45 °C (113 °F) HLP46
(HLP32 35 °C (95 °F)). This is achieved by opening and closing the cooling water valve on the
oil cooler.
If the oil temperature exceeds 60 °C (140 °F) HLP46 (HLP32 50 °C (122 °F)) , an error message
is shown on the screen. If the temperature exceeds 65 °C (149 °F) HLP46 (HLP32 55 °C (131
°F)), the control switches the machine hydraulics off.
The reason for the oil’s overheating must be established and the fault remedied (e.g. water
supply failure, cooling water shut-off valve on oil cooler closed.)
After operating the emergency stop button once, the hydraulics can be restarted. In this way, the
hydraulic oil is cooled. No movements (from the clamping and injection unit) are possible during
this phase.
ATTENTION
Take care of the conditions of installation and environment (Technical data chapter)!
SM1GB0MA
6.3.10 Hydraulic core puller
The hydraulic core puller (option) consists of a base plate on which the required hydraulic
valves are installed and which includes the user connections (NW 6 or NW 10).
Installation sites of the function modules:

Core puller Clamping unit: Ejector block
Core puller Nozzle side: Distributor block - base frame
The hose assemblies and fittings belonging to the mould’s core puller cylinder are not included
in the delivery.
It should also be noted that the maximum system pressure is 250 bar (3625 psi). All connections
and fittings must be able to withstand this pressure!
Hydraulic core pullers may be connected and put into operation only by a hydraulics
expert. The safety regulations in the "Safety" chapter are to be followed without fail!
SM1GB0MA
6.4 Pneumatics
6.4.1 Pneumatic core puller

The pneumatic core puller (option) comprises an electrically actuated 5/2 pneumatic valve and
all the consumer connections for a 6 mm (0.24 inch) bore plastic pipe.
This function module is mounted onto the central console or on the media block of the clamping
platen. The connection to the mould’s core puller cylinder is not supplied with the IMM.
ATTENTION
It should be noted that the compressed air used should be dried and lubricated and
limited to a pressure of 6 bar (87 psi). All connections and fittings must be able to
withstand this pressure!

The air supply unit (option for all pneumatic consumers) cleans the resource compressed air
from liquid and solid matter and controls the air pressure.
1 3
1 Setting knob pressure control valve

2 Condensate separator
3 Pressure gauge
4 Condensate reservoir
5 Drain screw
The air supply unit should be used only with properly processed compressed air without any
aggressive components.
A filter with a water trap separates the compressed air from solid contaminants and water. This
protects the pneumatic components fed by it from premature wear.
SM1GB0NA
Chapter 6.4 - 1
0115TW
SM1GB0NA

6.5 Airmould
The Airmould unit (option) enables the manufacture of high quality injection moulded articles
with gas voids by gas injection. For this reason, the injection moulding machine, for example,
may be operated with shorter cycle times and lower clamping forces.
The defining feature of gas injection is the filling of the mould cavity with two fluids. One fluid is
the polymer melt and the other is a gas, as a rule nitrogen (N2).
Danger of death! Only use nitrogen (N2) gas!
It must be ensured that the plastic processed does not return aggressive or contaminating
gases to the equipment.
The gas may be injected either via the machine nozzle or through needles in the mould
(injection modules).
The "Airmould unit" is made up of a gas pressure control and a compressor unit.
The main components of the gas pressure control are a pressure regulation module and an
electronic control unit integrated into the IMM "Control unit".
The pressure regulators for regulation of the gas pressure in the machine nozzle or mould
needles, are compactly built units and can thus be positioned very close to the gas injection
point. Four pressure regulators can be controlled by one standard electrical control.
EWAGB0OB
Chapter 6.5 - 1
0814TW
The main parts of the pressure generator are a high pressure compressor, drive motor, gas bag,
and accumulator bottles.
A nitrogen generator can be arranged as a separate unit or integrated into the pressure
generator, as the customer wishes.
EWAGB0OB

6.6 Electrics
6.6.1 Electric drive

6.6.1.1 Speed-controlled servo motor
The pump unit is driven by a speed-controlled servo motor.

The drive motor is coupled directly to the hydraulic pump and connected to suit the operating
voltage.
Service and connection work on the terminal rail may only be carried out by an
authorised electrician!
6.6.2 Switch cabinet

1 Switch cabinet Main cabinet
2 Switch cabinet Base frame
3 Switch cabinet Heating
1 3 2
SM1GB0PA
Chapter 6.6 - 1
0115TW
6.6.2.1 Switch cabinet layout Main cabinet
10 11 12 13 14 15 16 17
8 7 6 5 4 3 2
1 Main machine connection (main switch)
2 Mains filter according to the wiring diagram
3 Power choke, depending on the supply voltage
4 ACOPOS supply modules according to wiring diagram
5 Automation PC - undertakes control and visualisation tasks
6 PowerLink - ACOPOS/Panel (yellow)
7 Earth terminals
8 Safety relay
9 CAB PCB - Input/Output - Safety technology assembly, Input/Outputs and Options
10 Distribution terminals
11 X020 Modules - Input/Output - Assembly
12 Ethernet Switch
13 Main barrel heating contactor, optionally main mould heating connector
14 Sensor lines (green)
15 PowerLink (yellow)
16 Cable protecting device according to wiring diagram
17 Kers contactor
SM1GB0PA

6.6.2.2 Switch cabinet layout Base frame
3 2 1
1 Euromap 67 interface
2 Input/Output assembly Euromap 67 interface
3 Interface robot full integration
4 MB PCB - Input/Output - Assembly for inputs/outputs on clamping side and/or options
SM1GB0PA
Chapter 6.6 - 3
0115TW
6.6.2.2 Switch cabinet layout Heating
1
4
5
1 KERS
2 Nozzle heating
3 Power choke, depending on the supply voltage
4 PM8 control board
5 PM8 power board
6 Sockets for barrel heating
SM1GB0PA

Only qualified electricians may connect the machine to the electrical power supply
system. Switch off the on-site main switch and secure it against reconnection (e.g. by
means of a danger sign at the main switch).
In the factory the machine has been equipped with a PEN terminal for the connection to a TN-C
network (4 conductors).
• Open the switch cabinet
• Connect the mains cable to the mains switch and the PE terminal (to N and PE terminal
in the case of TN-S network)
• All clamping bolts in the switch cabinet must be checked for secure fitting and, if
necessary, retightened.
• Check the modules in the control insert and connection plug for secure fitting.
• Close the electrical cabinet
• Check all plug connectors of the control lines for the valves and safety switches for
secure fitting.
Only peripherical devices which correspond to the
VDO requirements and the EMC regulations (electromagnetic compatibility) of electrical
operating materials may be operated on the machine.
Cabling which was additionally fitted to the machine by the proprietor must correspond
to the EMC regulations (electromagnetic compatibility).
SM1GB0PA
Chapter 6.6 - 5
0115TW
SM1GB0PA

6.7 UNILOG B6 control

UNILOG B6 is a new generation of control units which sets the standard regarding operator
friendlinesss, speed and precision.
The continuity of the Battenfeld philosophy and symbolism regarding operation is ensured by
taking over the components from the previous control system - with an additional enlargement
of the graphical user interface.
A powerful system concept ideally adapted to the requirements of the hydraulic / sensor
system promotes quick and precise movements of all machine axes. The precise analysis of
all importent process variables provides the user with the control and supervision he needs for
demanding tasks.
6.7.2 Operator panel

The control panel is divided into:
• 15"-TFT colour monitor with unrestricted
touch-screen functions for operation and
display
• 2 rows with soft keys to select the
machine functions
• 48 membrane keys for operating
the machine axes and the optional
equipment
• Space for another 7 optional mechanical
switches / keys
• 10 luminous ring membrane keys are
available for the main machine functions
(drive, heaters, operating modes).
• 2 USB interfaces can be used for the
connection of data carriers (e.g. USB
stick, printer, keyboard) or as an access
system in combination with a password.
• More interfaces (2 USB and 1 Ethernet
interfaces) are located at the rear side in
the switch cabinet.
EWAGB0QC
Chapter 6.7 - 1
1214MC
6.7.3 Explanation of the picture
Flexibility
UNILOG B6 is a control concept which meets all demands concerning flexibility.
With the free core puller programming, the user can, for example, quickly and flexibly set core
puller sequences for different moulds. In standard operation, up to 8 core puller sequences can
be parameterised with a large number of logical operations.
EWAGB0QC
Chapter 6.7 - 2 1214MC

Holding pressure
The combination of tabular input and graphic represenation facilitates the setting of the machine
with the number of profile points being selected by ticking. A status bar on the extreme right of
the screen will quickly inform you on the current machine status. Furthermore, 3 configurable
status bars are available. By entering the machine settings in physical units and storing them on
an USB stick, machine data records can be exchanged among machines of different size.
EWAGB0QC
Chapter 6.7 - 3
1214MC
Actual value graphics
The most important means to assess the injection moulding process is the graphic
representation of pressure and speed developments during the injection or holding pressure
phase. The clear representation by the selection of curve numbers, different colours and the
numerical representation of peak values and actual values within the change-over point enables
a process analysis at a glance.
EWAGB0QC

Cycle time analysis
Analysis at a glance. The configurable cycle time analysis can be used for process optimisation
and, at a glance, shows the effects in the value change cycle to individual movements and/or
the total cycle. A complete overview is given by determining a reference cycle compared to the
previous and the current cycle.
EWAGB0QC
Chapter 6.7 - 5
1214MC
Alarm system
The production process can be backtraced by means of a comprehensive alarm / logging

concept with different filtering possibilities. Reaction times in the event of plant failures are
shortened by the automatic dispatch of email messages.
6.7.4 Saving / Printing

USB interfaces
Data / printouts can be stored / sent to USB data carriers and/or USB printers compatible with
WindowsTM by means of 2 USB interfaces located laterally on the operator panel and 2 other
USB interfaces in the switch cabinet.
Ethernet interfaces
1 Ethernet interfaces with RJ45 connections are available in the machine switch cabinet for the
integration in WAN/LAN networks, such as save / load machine data to / from a network server,
or send print jobs to a network printer server, or for the purpose of remote diagnosis.
EWAGB0QC

6.7.5 Control components
System structure
Overview of the Unilog B6 hardware structure
Touch display unit and key unit
Short-distance link connection (SDL)
Automation PC
Ethernet Powerlink connection (EPL)
X2X link / EPL connection
X2X I/O system
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Chapter 6.7 - 7
1214MC
Touch display unit AP9xx
The display unit is composed of two components: an automation panel device and an
automation panel link plug-in module. These two components, plugged together, build the
complete display unit. The resolution is 1024 x 768.
Automation panel 900
Automation panel link plug-in module
Cleaning:
The display unit may be cleaned only while the device is switched off in order to avoid the
release of unintended functions when touching the touch screen or pressing the keys or control
devices.
Use a moist cloth to clean the automation panel device. Only use water with a washing-up
liquid, screen cleaner, or alcohol (ethanol) for moistening the cloth. Do not spray the cleaning
agent directly on the automation panel device but spray it on the cloth! Under no circumstances
use aggressive solvents, chemicals, scouring agents, compressed air, or steam jet.
Clean the display with the touch screen at regular intervals.
EWAGB0QC

Automation panel link plug-in module SDL
The automation panel link plug-in module is the interface between an automation PC and an
automation panel 9xx. Graphic signals of an industrial PC (e.g. automation PC monitor / panel
output) are received, processed, and passed on to the automation panel 9xx. In the opposite
direction, the touch screen, USB and SDL data, for example, are transferred to the respective
interface of the industrial PC (e.g. automation PC). By means of simple slide-in technique, this
plug-in module is plugged into the slide-in slot of the automation panel 900 and fixed to the
automation panel by means of the two fixing screws (max. tightening torque 0.5 Nm).
Fixing screws
Display cable SDL cable 5CASDL.0xxx-00
Voltage supply
+24VDC In
Panel IN
(via SDL)
This cable is necessary for the transmission of the graphic / touch screen / USB signals
between display unit (automation panel link plug-in module) and automation PC.
ATTENTION
The SDL cable may be connected and disconnected in the dead state only.
Pin assignment
Casing Casing
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Chapter 6.7 - 9
1214MC
Key unit 5E9000.xx
Is used to operate the basic machine functions and special equipment. Due to the slide-in strip
technique, it can be easily adapted to customer wishes.
• Voltage supply: +24 VDC
• Bus interface: 2 x Ethernet Powerlink (EPL)
EWAGB0QC
Chapter 6.7 - 10 1214MC

Automation PC
The Automation PC with Intel® Core i technology is available for applications with the highest
demands in terms of processor performance. These processors, which were especially
developped for mobile computing, offers many advantages for industrial use, too. High
computer power is combined with low power input. The chip set includes an integrated graphics
with optimised storage utilisation between system and graphics.
The following individual components are absolutely necessary for operation:
• System unit
• CPU board
• Heat sink (depending on the CPU board)
• Main memory (depending on the CPU board)
• Drive (mass memory, such as Compact Flash card or hard disk) for the operating system
• Software
Interface Option 2
Interface Option 1
Monitor / panel / interface
Voltage supply
or
status LEDs:
* Depending on the bus type used:
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Chapter 6.7 - 11
1214MC
Battery:
A lithium battery (3 V, 950 mAh) buffers the internal real-time clock (RTC) as well as individually
stored BIOS settings and is located under the black cover. The buffer duration of the battery is
at least 4 years (at 50°C, 8.5 μA of the components to be supplied and a self-discharge of 40%).
status LEDs:
Power key
Reset key
Battery
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Chapter 6.7 - 12 1214MC

I/O modules
Three basic elements form a single module: Bus module - electronic module - field terminal
1 5
2 6
3 7
4 8
1 Easy installation - ingenious top-hat rail installation for optimum system handling
2 Stable triangle arrangement - direct connection between bus module and terminal block
3 Wide range of products - allows optimum adaptation for every task
4 Galvanically insulated - reliable operation under the toughest conditions
5 Diagnosis - on-site visual diagnosis, remote via software and electronic type plate
6 12x field terminal - ensures maximum packing density
7 Push-in terminals - no tools required for the handling of all standard connection cross
sections
8 Coding - seamless works and customer coding
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Chapter 6.7 - 13
1214MC
X20BR9300
The X20 System is connected to the X2X Link with the bus receiver BR9300. The module is
equipped with a feed for the X2X Link and the internal I/O supply.
Alternativ zu X20BR9300 -> X20BC0083/X20PS9400
X20BC0083
The BC0083 Bus Controller enables the connection of X2X Link I/O nodes (modules) to
POWERLINK (standard protocol for Fast Ethernet).
X20PS9400
The PS9400 supply module is used together with an X20 Bus Controller (e.g. X20BC0083). It is
equipped with a supply for the Bus Controller, the X2X Link and the I/O supply.
X20DI9371
The module DI9371 has 12 inputs in single conductor technology. The DI9371 is designed for
sink input wiring.
X20DO6322
The module DO6322 has six outputs in single or doubleconductor technology. The X20 standard
terminal can be used 6x for continuous single conductor wiring. Double conductor wiring is
possible with the 12x terminal. The DO6322 is designed for source output wiring.The nominal
output current is 0.5 A.
X20DO9322
The module DO9322 has 12 inputs in 1-conductor technology. The DO9322 is designed for
source output wiring. The nominal output current is 0.5 A.
X20DO8332
The module DO8322 has eight inputs in 1-conductor technology. The nominal output current is
2 A. The output supply is fed directly at the module. This means that no additional feed module
is necessary. There is no connection from the module to the I/O supply potential on the bus
module.
X20AI4632
The module AI4632 has four inputs with 16-bit digital converter resolution. It can be switched
between current and voltage signal (+/- 10 VDC) with the aid of different connection terminals.
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Chapter 6.7 - 14 1214MC

X20AO4632
The module AO4632 has four outputs with 16-bit digital converter resolution. It can be switched
between current and voltage signal (+/- 10 VDC) with the aid of different connection terminals.
X20AT6402
The module AT6402 has six inputs for J, K, N and S thermocouple sensors. A terminal
temperature compensation is integrated in the module.
X20PS4951
The module PS4951 has four +/-10 VDC voltage supply channels for the potentiometer supply.
CS 1070
The CS 1070 module is equipped with a CAN bus interface. Furthermore, an additionally
connectable terminating resistor is included.
CS 2770
The CS 1070 module is equipped with 2 CAN bus interfaces. Furthermore, an additionally
connectable terminating resistor is included.
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Chapter 6.7 - 15
1214MC
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Chapter 6.7 - 16 1214MC

7 Operation
For a number of reasons we would recommend commissioning of the IMM by Battenfeld

personnel. This is not only for warranty reasons, but because at the same time:
• The machine can be checked for any transport damage or installation and connection
faults.
• The operating personnel will be introduced to the IMM.
• Additional advice on operation, maintenance and repair can be given.
Magnetic field hazard! In the immediate proximity of the magnetic fields of magnetic
quick-action mould mounting systems (option), cardiac pacemakers, hearing aids, or
disks etc. will be impaired!
These magnetic fields will still be present after switching off the machine at the main switch.
Only after demagnetising the magnetic modules will the magnetic fields be neutralised, i.e. the
hazard will no longer be present.
CAUTION
Every 2500 operating hours, the barrel heater bands must be checked for tightness at
operating temperatures!
Check the nitrogen pressure in the pressure vessel (option) at regular intervals as
described in this chapter!
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Chapter 7 - 1
0714MC
7.2 Initial start-up
ATTENTION
For test purposes, the injection unit was operated with the following material:
Polystyrene STYROLUTION PS 454N (HIPS) processing temperature 180°-260 °C/356°-500 °F
If required, rinse screw barrel with a suitable cleaning material.
1 Observe the operating manual and in particular the safety regulations in the "Safety" section.
2 Unload, transport, install and level the machine as described in the "Transport - Installation"
section.
3 Prepare the hydraulic system as described in the chapter "Transport - Installation".
4 Prepare the water system as described in the "Transport - Installation" section.
5 Turn on water supply to oil cooler
6 Prepare the pneumatic system as described in the "Transport - Installation" chapter
7 Open the air supply from the compressed air system to the air supply unit (option),
mechanical scotch (option).
8 Prepare the electrical equipment as described in the chapter "Transport - Installation".
9 Switch on the supply voltage (low voltage distribution).
10 Ensure that there are no highly combustible and explosive air mixtures near the screw barrel
heating
11 Ensure that no easily combustible materials, e.g. styrofoam, rags etc., or explosive air
mixtures are near the inlets of the radial fans.
12 Lubricate lubrication points, as described in the "Transport - Installation" chapter
13 Prepare the Airmould unit (option) as described in the "Airmould" chapter.
For the preparation of a mobile Airmould unit (option) please refer to the separate operating
manual.
14 Switch on drive ("Drive On" key).

The standard machine has an oil preheating system, and can not be run until a
hydraulic oil’s operating temperature has been reached (after about 15 min.).
15 Clear any error messages which appear (see "UNILOG B6 User’s Manual", "List of all alarm
messages" section).
16 Mount the mould as described in the "Transport - Installation" chapter and adjust the
clamping force.
17 Connect the peripheral equipment (option) as described in the "Transport - Installation"
chapter
18 Check the safety device as described in the "Transport - Installation" chapter
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19 Open and close the safety gate and purge guard (to test the safety gate monitoring
circuit)
It is forbidden to stand on the machine or to reach into the injection unit during
operation!
20 Carry out the test run and interlock test as described in the "Transport - Installation"
chapter
21 Carry out the test run without / with material as described in the present section.
22 Select the operating mode and start the machine.
7.3 Starting the machine after EMERGENCY STOP

The emergency stop button is a safety switch for shutting the machine down quickly in the case
of danger. If it has been operated, it must be released after the fault or the cause of the external
emergency stop (periphery, e.g. the robot) has been cleared, by turning it in the direction of the
arrow. Then the machine is switched on again as described in the paragraph "Operation", and if
necessary, the mould cleared of the moulding by means of the ejector.
The starting position of the machine is: Mould fully open, ejector, nozzle and screw back, core
puller (option) out.
7.4 Checking the nitrogen pressure

Check the nitrogen pressure in the pressure vessel (option) before and during operation. In
case the nitrogen pressure falls short of the indicated value (see name plate), nitrogen has to be
refilled.
The safety regulations in the chapter "Safety" are to be followed without fail!
Work at pressure vessels may only be carried out by specially trained personnel!
For instructions on how to refill, reduce and check the nitrogen pressure, please refer to the
"Transport - Installation" chapter.
1 Check at least once within the first 40 operating hours. Major losses in nitrogen will
immediately be detected and be compensated.
2 In case no losses have been detected during the first inspection, the next inspection is to
be carried out after 500 operating hours.
3 After this inspection further inspections may be carried out at an interval of 1000
operating hours.
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Chapter 7 - 3
0714MC
7.5 Test run without material
After commissioning or changing the mould, the movements of the various units should be
tested before running a few manual cycles with a mould mounted.
1 Check whether the switch cabinet, safety guards and safety gates have been properly
installed or closed.
2 Clear inside of the machine of all foreign bodies (forgotten mould).
3 Switch on the supply voltage (low voltage distribution) - commissioning only.
5 Release the emergency stop button(s) on the machine by rotating a quarter of a turn
clockwise.
6 Open the water supply from the cooling system to the individual users (oil cooler, cooling
water flow governor, etc.) - commissioning only
7 Open the air supply from the compressed air system to the air supply unit (option),
mechanical scotch (option) - commissioning only.
9 Open and close all safety gates once (to test the safety gate
monitoring).
Press the "Open safety gate" and "Close safety gate" keys in case of a
power-operated safety gate (option).
10 Switch on drive ("Drive On" key).

This action also starts the oil preheating. Now, you have to wait until the
hydraulic oil is heated up to a minimum of 40 °C (104 °F) HLP46 ((30 °C
(86 °F) HLP32)
Start the pump without load and run it for a few seconds to allow for adequate
lubrication.
11 Switch on bypass filtration unit (option).
HC6GB0RC
Before operating the machine the safety regulations in the operating manual(s) of any
peripheral equipment must be followed without fail!
12 Commission peripheral equipment (option) according to the operating manuals and set
them to the starting position, i.e. the position in which no damage to the devices or to
machine components is possible.
13 Clear any error messages which appear (see "UNILOG B6 User’s Manual", "List of all
alarm messages" chapter).
15 Log on to the control.

An activation of the key symbol opens the window for "System password".
For the log on to the control refer to chapter A 7 in the control unit’s manual.
16 Setting the set values

(see B6 user manual)
The set values for "Injection" are to be set as low as possible for a respectable injection
cycle. Otherwise the mould can possibly be overpacked. When opening the mould and
using magnetic quick-action mould mounting systems (option) in particular the chucking
power can be exceeded.
For moulds with a smaller base the ejector force may exceed the retention force of the
clamping elements which will cause the mould to disengage.
During operation "without material" it is necessary that no shot volume is entered,
thus the set value is 0. In this, case the screw is only to be retracted by means of
decompression in order to avoid the injection of material.
Set the set values for "Injection", "Locking force" and "Ejector" as low as possible for
an acceptable injection cycle. Otherwise forces may be present when opening the mould
which can possibly exceed the limit range of the clamping elements!
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Chapter 7 - 5
0714MC
Fire hazard! No smoking! Make sure that there are no flammable liquids, open flame, etc.
near the screw barrel heating or barrel cooling (option)!
No drawn-in material or explosive air mixtures may be near the inlet area of the radial
fans to the barrel cooling (option)!
17 Remove all materials, liquids and objects which should not be near the injection unit.
18 Press "Heating on" key (switch on barrel heating).

(see B6 user manual)
19 Bring the machine to the following starting position:
Mould open
Ejector fully back
Nozzle back
Screw back
Core puller out (option)
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20 Press "Automatic mode" key.
Operating and other personnel may only stand in front of the machine on the operator’s
side during operation!
21 Press "Mould close" key; an automatic cycle is started.

The "Semiautomatic" modes can be started by closing the safety gate (option).
In case of power-operated safety gates at the clamping unit, these gates will be opened
automatically at the end of the cycle in the "Semiautomatic" operating mode.
During the test run, listen for any unusual noises and check the function of the safety
gates.
The "Fully automatic" and "Semiautomatic" modes are interrupted by pressing the
"Manual mode" key or an emergency stop button.
Any leaks which arise in the first few operating hours can usually be cured simply by
tightening the screw connections.
22 The "Automatic" operating mode can be stopped at the end of the cycle by pressing
the "Open mould" key during the cycle. In this case, the error message "manual end of
production initiated" is displayed. After the cycle has been interrupted, further operation
can be initiated by pressing the "Close mould" key.
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Chapter 7 - 7
0714MC
7.6 Filling the material hopper
1 Make sure that the main switch is switched off and secured against unauthorised
reconnection.
Surfaces marked with the "No step” symbol must not be stood on!
If the material hopper, the material feeder or the stuffing device are located higher than
the average body height, climbing aids and working platforms which meet the legal
safety requirements must be used for filling!
2 Move the climbing aid in front of the machine.

3 Clean the material hopper and check for foreign particles. For this reason the use of open
material bags should be avoided.
Follow the plastic manufacturers’ instructions!

When processing plastics which give rise to harmful gases dusts or vapours, the
proprietor of the machine has a duty to provide suitable extraction for the protection of
operating personnel!
CAUTION
The operator has a duty to ensure no foreign bodies enter the material hopper of barrel
throat!
4 Place material hopper to mid position.

5 Fill in material
6 Place material hopper above the feed throat of the screw barrel.
7 Remove climbing aid from the working area of the machine.
HC6GB0RC
7.7 Test run with material
1 Prepare the machine as described in chapter "Test run without material", steps 1 to 3.
2 Fill material as described in section "Filling the material hopper".
3 Prepare the machine as described in chapter "Test run without material", steps 4 to 18.
4 Preselect the metering profile (shot volume) correspondingly.
6 Open mould; move ejector and nozzle back; move core puller back, if necessary
7 Drive screw forward ("Injection" key)
8 Press "Metering" key and carry out a manual metering process.
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Chapter 7 - 9
0714MC
9 Select the desired program "Automatic” or "Semiautomatic”
Depending on the program selection either press the "Close mould" key or
close the safety gate (see step 22 in the "Test run without material" section) to
start the machine.
In this way several cycles are run.
The movements of the various units, the settings and the quality of the mouldings are now to
be checked. Depending on the application, appropriate corrections are made to the various set
values in order to achieve the quality required for the moulding.
Once all the set values have been entered, they can be saved to avoid unnecessary data loss.
For additional security the set values complete with mould number and part number should be
printed out and placed in the Operating Manual.
For procedure see the UNILOG B6 User manual, chapter 25 "Data records".
10 Log off from the control
CAUTION
To prevent set value entries by unauthorised persons, the user must log off after
finishing setting!
10.1 An activation of the key symbol opens the window for "System password".
If you want to interrupt or finish your work at the control unit, you will have to logout first.
This procedure prevents unauthorised input at the control unit.
10.2 Select the "Logout" key.
If the logout is successful, the window is automatically closed. As an acknowledgement,
user level 90 is displayed in the "User level symbol".
HC6GB0RC
7.8 Operation
The operation of the machine does not differ from the procedure described in paragraph "Test
run with material" and the procedures described in this section.
After each shutdown and before each start-up of the machine, the safety devices have
to be checked after switching on the main switch as described in the "Transport -
Installation" chapter!
For the first few hours in which the machine is used under production conditions, the following
should be monitored in particular:
1 The hydraulic oil temperature.

The optimum efficiency of the hydraulic oil is between 45 °C und 50 °C (113 °F und 122
°F) HLP46 (35 °C und 40 °C (95 °F und 104 °F) HLP32).
The current oil temperature will be displayed on the "Hydraulics" screen page.
2 The proper fit of the tiebar nuts.
The tiebar nuts may loosen due to the constantly changing loads. Therefore, the clamping
plates of the tiebar nuts must be tightened and checked for security after the first 100
operating hours.
3 The screw barrel heater bands
The barrel heater bands must be checked every 2500 operating hours for security at
operating temperatures.
4 The nitrogen pressure within the pressure vessel (option); see "Checking the nitrogen
pressure" chapter.
Periodical checks should be performed during operation at regular intervals and according to
the procedure described in the "Maintenance" chapter.
Visible defects are to be remedied immediately.
Remedy damage immediately. Hydraulic oils escaping at high pressure can cause severe
injuries and fires!
This applies especially to hydraulic fittings and hose assemblies.
HC6GB0RC
Chapter 7 - 11
0714MC
7.9 Shutting down the machine
2 Set peripheral equipment (option) to the starting position and switch off any peripheral
equipment according to its operating manual.
3 Pull the hopper away from the feed throat of the barrel
4 Move the core pullers out of the mould if appropriate.
5 Move the clamping platen to the starting position (Mould open). If necessary remove the
moulding(s) from the mould using the ejector
Burns hazard! Do not touch escaping material!
6 Swing the material hopper from the inlet area of the screw barrel to the centre position
7 Press the "Injection unit back" key.
8 Place an appropriate reservoir in front of the nozzle and purge the remaining material at
short intervals.
9 Switch off drive ("Drive off" key).
10 Switch off the heater ("Heater off" key)
11 Close and relief the cooling water supply (add antifreezing agent, if necessary) from
pressure
12 Close and relieve the compressed air system (option) from pressure
HC6GB0RC
7.10 Extended shutdown
1 Shut down the machine as described in "Shutting the machine down”.

Swing the material hopper to the emptying position and fill the remaining material into an
appropriate container.
2 First free the screw barrel and the screw from the remaining melt and purge out with
polyethylene.
3 Depending on the material to be processed, the nozzle and the screw must be removed
and cleaned.
4 Preserve the cavities of the mould according to the manufacturer’s instructions.
5 For a hydraulic system with integrated pressure accumulator (option) deflate the nitrogen
as described in section "Transport - Installation".
6 Treat all bare parts with a anticorrosive agent.
7 Empty the cooling water system, blow out with compressed air and treat with
anticorrosive agent
HC6GB0RC
Chapter 7 - 13
0714MC
7.11 Shut down procedure
1 Shut down the machine as described in "Shutting the machine down”, steps 1 to 10
2 Preserve the cavities of the mould according to the manufacturer’s instructions.
7.11.1 Dismantling the mould

In this paragraph the dismantling of a mould fastened with mould clamps is described.
The dismantling of a mould fastened with a quick-action mould mounting system basically
corresponds to the following description. The only differences will be in the Remove mould
of the clamping platen / nozzle platen paragraphs. To this end use the appropriate control
elements at the operator panel. See also paragraph "Mould mounting using quick-action mould
mounting systems" in the "Transport -Installation" chapter
1 Press the "Mould Close" key and close the mould.
The mould may only be dismantled by an authorised skilled technician!
2 Disconnect the ejector coupling (mould to hydraulic ejector cylinder).
Burning hazard if touched! At mould temperatures above 60 °C (60,00 °C) wear

appropriate PPE!
3 Let the mould cool down to a safe temperature (material dependent).

4 Prepare the mould for dismantling (Disconnect cooling hoses, heating cables etc.).
HC6GB0RC
5 Mount the safety strap holding the two mould halves together.
The safe working load of the lifting equipment must equal or exceed the weight of the
mould!
6 Mount the lifting gear at the mould.
7 Slightly tension the lifting gear.

8 Press the "Setting" key.
9 Loosen the mounting elements of the mould on the clamping platen.

10 Move the clamping platen back.
11 Loosen the mounting elements of the mould on the nozzle platen.

12 Remove them from the centering hole in the nozzle platen.
HC6GB0RC
Chapter 7 - 15
0714MC
Danger of death! It must be ensured that no persons stand or linger under the suspended
load!
13 Lift the mould horizontally out of the opened clamping unit.
14 Protect the mould according to the mouldmaker’s instructions and prepare it for storage.
7.11.2 Further measures for shutting down

1 Let the heating elements and their guardings, temperature control units and their flow and
return lines and their couplings and mounting elements cool down to a safe temperature.
2 Move the piston rods of the hydraulic cylinders in the setting mode as far as possible into
the hydraulic cylinder to protect them from corrosion.
In case of a possible disassembly, release any remaining pressure by carefully loosening
(but not completely undoing) the appropriate hydraulic screw connection.
If the place of installation is to be changed, the clamping and the injection unit has to be
moved to the transport position as described in "Changing the place of installation".
3 Press "Drive stop" key.
4 Turn off the main switch and use a padlock to prevent accidental reconnection.
Cleaning materials are classed as flammable liquids, hazardous to health. The

manufacturer’s instructions are to be followed without fail!
5 Dismantle nozzle (and nozzle head) as well as screw and screw barrel and clean them.
HC6GB0RC
7.11.3 Emptying the hydraulic system
Work at the hydraulic system may only be carried out by a skilled hydraulic technician!
1 For a hydraulic system with integrated pressure accumulator (option) deflate the nitrogen
as described in section "Transport - Installation".
Burning hazard if touched! At oil temperatures above 50 °C (50,00 °C) wear appropriate
PPE! Avoid any skin contact! If hydraulic oil gets into the eyes, rinse carefully with water
and consult a physician!
2 Clean the area round the venting filter.

3 Thoroughly clean the area around the filler and screw plugs on the transport and storage
containers.
4 Unscrew the venting filter lock and remove the complete venting filter from the pipe
socket.
Fire hazard! No smoking! Make sure that there are no flammable liquids, open flame, etc.
nearby!
Environmental hazard! In case of leaking hydraulic oil follow the legal provisions and
regulations without fail!
5 Empty the hydraulic tank by means of a pump unit via the pipe socket. The suction hose
must reach to the bottom of the hydraulic tank.
The pump unit must be permissible for hydraulic systems.
The tank must be approved in accordance with the applicable laws and regulations and
must be dimensioned to be able to hold the hydraulic oil volume (see "Technical Data"
section).
HC6GB0RC
Chapter 7 - 17
0714MC
6 Place the venting filter on the pipe socket again.
7 Clean the hydraulic tank
8 Remove the housing of the hydraulic filter. Dispose of the liquid in a suitable container,
see chapter "Maintenance", "Hydraulic filter" paragraph.
When storing and disposing of hydraulic oils and used oil the local laws and regulations
are to be followed without fail. The proprietor of the machine is responsible for proper
waste disposal!
When disposing of the oil pan and cloths drenched with hydraulic oil the laws and
regulations applicable must be followed without fail. The proprietor of the machine is
responsible for proper waste disposal!
HC6GB0RC
7.11.4 Emptying the cooling water supply
Burning hazard if touched! At water temperatures above 50 °C (50,00 °C) wear

appropriate PPE!
1 Cut off the water supply to the oil cooler

4
2
3
3
5
2 Cut off the water supply (1) to the cooling water flow control.
3 Turn the two hand-wheels (2+3) of the cooling water flow control counterclockwise (Close
cooling water flow).
4 Disconnect the cooling water supply and return lines from the oil cooler
5 Drain the cooling water from the supply and return lines of the oil cooler to appropriate
systems or containers
6 Disconnect the cooling water return (4) from the cooling water flow control and drain the
cooling water to appropriate systems or containers.
7 Disconnect the cooling water flow (1) from the cooling water flow control and drain the
cooling water to appropriate systems or containers.
8 Turn both hand-wheels (2+3) of the cooling water flow control cw (Open cooling water
flow) and drain the cooling water to appropriate systems or containers
9 Disconnect the cooling water flow and return (5+6) of the users and drain the cooling
water to appropriate systems or containers
10 Connect the compressed air hose to the supply lines of the oil cooler and the cooling
water flow control and blow out with compressed air.
11 Drain the remaining cooling water from the supply and return lines to appropriate systems
or containers
12 Insert plugs into the fittings of the supply and return lines to protect them against
contamination
HC6GB0RC
Chapter 7 - 19
0714MC
7.11.5 Evacuating the compressed air system
If the compressed air system is not relieved of all pressure before work starts, there is a
risk of explosive emptying with possible damage or injury!
1 Cut off the compressed air supply to the air supply unit.
1
2
2 Turn the pressure control valve setting knob (1) counterclockwise until the pressure
gauge (2) has dropped to 0 bar.
3 Turn venting screw (3) counterclockwise.
4 Turn condensate drain screw (3) counterclockwise; drain condensate to a suitable
container; turn condensate drain screw clockwise.
7.11.6 Other measures

1 Follow the procedures in the respective operating manuals without fail before shutting
down the peripheral equipment.
2 All bare and unplated moving parts and guides (tiebars, piston rods, etc.), and all
unpainted, unplated bolts must be preserved using an oily rust preventing agent.
HC6GB0RC
7.11.7 Disconnecting the electric system
The machine may only be disconnected from the power supply by a skilled electrician.
1 Switch off the supply voltage (low voltage distribution) to the machine.
2 Disconnect the supply lines in the switch cabinet from the mains and the heating power
terminals.
3 Secure the supply lines against interference according to locally applicable regulations.
4 Place desiccant medium for protection of connecting terminals, relays, etc. from corrosion
into the electrical cabinet.
7.12 Measures after an extended shutdown

1 Clean the machine from dust and rust preventing agent, see chapter "Transport -
Installation".
2 Note the service life of the hydraulic hoses and hose assemblies, see chapter
"Maintenance".
3 To prevent the hydraulic pump(s) from being damaged, check whether they are filled with
hydraulic oil; see chapter "Transport - Installation".
4 Replace the "Hydraulic filter" and "Venting filter" filter elements; see chapter
"Maintenance".
The isolation value may only be checked and moist windings may only be dried by a
qualified electrician. The safety regulations in the chapter "Safety" are to be followed
without fail!
5 Check the insulation values of the hydraulic motors windings.

6 Observe the service life of the battery in the control unit; see chapter "Maintenance".
7 Prepare the machine according to section "Transport - Installation".
8 Proceed in the same order as described in "Test run without material" to "Test run with
material"
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Chapter 7 - 21
0714MC
9 Maintain hydraulic system
After extended shutdown, in particular, if there are extreme climatic conditions, the
movement of some hydraulic components (e.g. valves) may be restricted due to gumming
or precipitations within the hydraulic oil. For this reason the machine should be carefully
restarted at low set values for the movement speeds and pressures. Carefully observe
whether all hydraulic functions have been carried out and the proper function of the
machine is ensured.
If necessary, the machine should be filled and flushed out with a cleaning oil (HLPD
according to DIN 51524 Part 2, Class ISO VG 32). These are hydraulic oils with cleaning
additives (identifying letter "D" = "detergents").
After successful flushing, the machine should be refilled and used with the standard
hydraulic oil (HLP32/HLP 46).
10 Follow the procedures in the respective operating manuals without fail before restarting
the peripheral equipment.
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7.13 Changing the place of installation
1 Prepare the machine as described in "Shut down procedure".
2 Move the injection unit to its foremost position (into the nozzle platen) before changing
the place of installation
3 Move the clamping platen to the "Mould open" position and adjust the maximum mould
mounting height.
4 Open the clamping unit’s safety gates on the operator’s side and the rear and secure by a
rope, around the machine frame tied to each handle.
5 Remove foundation bolts if necessary.
6 If the machine is to be moved to an external installation site, lift it using the appropriate
lifting equipment, see chapter "Transport - Installation" and dismantle the levelling
mounts.
7 Attach lifting equipment as described in paragraph "Transporting the machine" in chapter
"Transport - Installation".
8 Transport the machine using the appropriate means of transportation (fork lifting truck,
crane) as described in chapter "Transport - Installation"
9 If the machine is to be moved to an external installation site, secure the IMM with ropes
suitable for the weight of the machine on the means of transportation (e.g. truck)
The complete machine may only be placed on a level surface capable of supporting the
appropriate load.
10 Unload, install, level and commission the machine at the new installation site as
described in chapter "Transport - Installation"
HC6GB0RC
Chapter 7 - 23
0714MC
7.14 Disposal
The proprietor is obliged to dispose of all components, lubricants, hydraulic and gear
oil as well as other aids (cleaning cloths, cleaning agents, etc.) according national and
international laws and regulations.
This applies especially to those components which have been in contact with products
hazardous to the environment (lubricants, hydraulic and gear oils).
Please contact the responsible authorities before disposal. You will receive detailed information
on laws and regulations applicable, the facilities for disposal as well as on authorised waste
disposal companies.
Ask your lubricant supplier for the safety data sheets according to DIN 52900 for the products
they supply you with. Among others, these contain information on waste disposal.
If possible, the materials and substances should be recycled.
The provisions on waste disposal within the European Union (EU) can be found in the
"Europäischen Abfallkatlogverordnung" (EAKV) ("European Waste Disposal Catalogue
Regulation"). This regulation is to translate the provisions of the decision 94/3/EC on a waste
disposal directory according to Article 1, section a of the Directive of the Council 75/442/EEC on
wastes into the German legislation.
In the Directive of the Council 75/442/EEC measures on the avoidance, recycling and the
disposal of wastes are described in Article 3; Article 4 contains the compliance with the principle
of non-hazardous waste recycling and disposal. Article 5 stipulates the principles of the nearest
possible and self-reliant waste disposal.
HC6GB0RC
8 Maintenance
8.1 Miscellaneous
Careful installation and care are necessary for the reliable functioning of the injection moulding
machine (hereinafter machine).
Daily visual checks help to prevent down times. Checks, maintenance work and the exchange
of worn out parts should be undertaken at regular intervals. Only parts of the same quality
(strength, material) and design may be used.
Breakdowns of the machine caused by inadequate or improper maintenance can result in very
high repair costs and long periods of down time. Regular maintenance is therefore essential.
If you have questions about maintenance or service of the machine, please contact our
Technical Service Department or one of our subsidiaries. The addresses can be found in the
"Customer service" chapter.
The safety regulations in the "Safety" chapter are to be followed without fail!
Before starting any maintenance or repair work the main switch of the machine must be
switched off and secured against accidental reconnection!
8.2 Transport, storage and disposal of lubricants
Lubricants and hydraulic oils are environmentally hazardous products. For this reason,
the local environmental laws and regulations concerning water, building, waste,
transport, trade and safety at work must be observed.
These areas of legislation include the fields of transportation, storage and waste disposal.
Even the strictest compliance with all laws and regulations does not preclude accidents with
lubricants. In such cases the appropriate authorities (Water Board, Police, Fire Brigade) must
be notified immediately. The amount of lubricant discharged before notification is required varies
from place to place.
There is therefore a need to make contingency plans for preventive measures in the case of
any incident with oil. This includes the existence of such a plan itself, that sufficient oil absorbing
medium is in stock, that drains can be closed off and that tools and materials are available to
prevent the spilled oil from escaping.
SM1GB0SA
Ask your lubricant supplier for the safety data sheets according to DIN 52900 for the products
they supply you with.
These cover:
• Chemical and physical properties.
• Protective measures, storage and handling.
• Measures to be taken in the event of accidents and fires.
8.3 Disposal of electrical and electronic components
When disposing of electrical and electronic components, the local laws and regulations
are to be observed.
8.4 Hydraulic oil and lubricant table
ATTENTION
New machine:
In principle, a test run of the machine in the factory is carried out with zinc-containing
oil. However, the machine can also be operated with a comparable zinc-free oil When
delivered, the remaining amount is approx. 5 %, therefore you must ask the respective oil
supplier whether operation is possible when mixing is done in this ratio.
Second-hand machine:
In consultation with the manufacturer / supplier of the oil, the operating company may -
upon its own responsibility, change the oil type from zinc-containing to zinc-free oil.
In principle, such a change of oil type should not be made since extensive technical
problems could be caused.
Wittmann-Battenfeld will not grant an approval!
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Only use prefiltered hydraulic oil of cleanliness class 17/15/12 acc. to ISO 4406!
Central lubri- Three-phase High -
Hydraulic Hydraulic Gearbox, Central oil
Lubrication point cation grease motor & electric Pneumatics Linear guide assembly
equipment*) equipment***) axial bearing lubrication
and grease motors**) paste
Designation to HLP 46 HLP 32 CLP 220 CG 220 K 2/3 R - 40 HLO 10 / CL 10 KP2 N-20 DIN
DIN 51502 DIN 51524 T2 DIN 51524 T2 DIN 51517 T3 DIN 51517 T3 DIN 51825 DIN 51524 T1 51825
Agip Agip Agip Agip ASP 220 Agip

-
OSO 46 OSO 32 Blasia 220 Agip Exidia 220 ACER 10
Aral Vitam Aral Vitam Aral Degol Aral Deganit Aral Vitam
-
GF 46 GF 32 BG 220 B220 DE 10
AVIA FLUID AVIA FLUID AVIA GEAR Slideway oil AVIA FLUID
-
RSL 46 RSL 32 RSX 220 RSU 220 RL 10-C
BP Energol BP Energol BP Energol BP Maccurat BP Energol

-
HLP-HM 46 HLP-HM 32 GR-XP 220 220 D HLP-HM 10
Castrol
Castrol Hyspin Castrol Alpha Magnaglide Castrol Hyspin SPERROL
Hyspin SLX Grease
AWS 32 SP 220 D 220 AWS 10 EPL2
AWS 46
SPARTAN FEBIS
NUTO H 46 NUTO H 32 - SPINESSO 9
EP219 K 219
HYDRAN HYDRAN
GIRAN 220 HYDRAN G220 Pluton EM CIRKAN 10
TS 46 TS 32
Mobil Mobil Mobilgear Mobil Vactra Mobil Velocite

-
DTE 25 DTE 24 630 Oil No. 4 Oil No. 6
RENOLIN RENOLIN
RENOLIN CLP RENEP RENOLIN B 3
B 15 B 15 -
220/220 Plus CGLP 220 VG 10
VG 46 VG 32
Q8 Q8 Q8 Q8 Q8
-
Haydn 46 Haydn 32 Goya 220 Wagner 220 Haydn 10
Shell Tellus Shell Tellus Shell Omala Shell Tonna Aero Shell Shell Morlina
Alvania WR2
S2 M 46 S2 M 32 S2 G 220 S3 M 220 Grease 16 S2 BL 10
TUNGEAR TUNGEAR
TUNGREASE TUNGREASE TUNGREASE
CGLP 220 CGLP 220
CSH2 (H1****) CSH2 (H1****) CSH2 (H1****)
(H1****) (H1****)
TNK Hydrau- TNK Hydraulic TNK Reductor

- - - -
lic HLP 46 HLP 32 CLP 220
Lukoil Geyser Lukoil Geyser Lukoil Steelo

- - - -
ST 46 ST 32 220
Gazpromneft Gazpromneft Gazpromneft

Hydraulic Hydraulic HLP Reductor CLP - - - -
HLP 46 32 220
WEICON
Anti-Seize
High-Tech
*) Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO 4406; always prefilter!
**) Only for air cooled three-phase motors
***) For ServoPower (Option). Hydraulic oil: Only use oil of the cleanliness class 15/12 to ISO
4406; always prefilter!
****) H1 Food quality
SM1GB0SA
8.5 Maintenance chart
Every 160 operating hours
2 1 4 2 4
• All safety devices (1) or all safety guards installed (2) (including the mechanical scotch)
• Oil level in hydraulic tank (3)
• Overall condition of machine (visual check).

• Always keep the electrical cabinet closed
• Check the filter mat(s) in the electrical cabinet fans for clogging.
• Check hydraulic fittings, hose assemblies, cylinders, valves, pump(s) etc. for leakages
• Check air conditioning units (condensation water tank, filter), if present

• Check water piping and the respective fittings for corrosion and leakages
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• Spray all bare parts (tiebars, piston rods, guide rails, linear bearings injection units),
where there is no movement with a corrosion inhibitor
• Lubricate grease points on linear guide
• Remove emerging lubricating grease.

• Check scotch bar (option) for proper function
• Clean filter element of air supply unit (option)
• Checking the nitrogen pressure

• Operating manual available and correct.
• Check the heater bands for correct position and secure fitting.
• Clean the switch cabinet, tighten all terminals in the switch cabinet, check cables (for
damage, scorching)
• Clean the filter mat(s) of the switch cabinet, fan

• Test the emergency stop circuit.
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• Check screw coupling and retighten screws if necessary.
• Replace hydraulic tank venting filter

• Check all stroke transducers for cleanliness and ease of operation.
• Visual check of electrical components.

• Check nozzle for wear and concentricity
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• Test hydraulic oil (replace if necessary)
To establish the oil change interval suitable for the local operating conditions it is
recommended to test the oil at first after shorter intervals (e.g. monthly).
• Replace filter element of the hydraulic filter.
• Check all fittings for security and tighten as necessary.

• Check of insulation resistance and of the protective-conductor system.

• Change hydraulic hose assemblies
• Flush oil cooler and cooling water flow governors with a descaling solution.
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8.6 Hydraulic system
Work on hydraulic system may only be carried out by a skilled hydraulic technician!
Switch off the main switch and use a padlock to prevent accidental reconnection. If the clamping
platen, nozzle and screw are not in one of their end positions then the hydraulic system is
relieved from pressure. Any residual pressure can be released by carefully loosening (but not
completely undoing) a hydraulic screw connection.
8.6.1 Oil change
Burning hazard if touched! At oil temperatures above 60 °C (60,00 °C) wear appropriate
PPE!
When disposing of used oil, legal requirements must be met. The proprietor of the
machine is responsible for proper disposal!
Every 5000 operating hours an oil sample should be taken and, depending on the analysis,
an oil change be carried out. This assumes a maximum operating temperature of 60 °C (140
°F) (with ServoPower (Option) 50°C (122°F)) and regular oil filter changes. To establish the oil
change interval suitable for the local operating conditions it is recommended to test the oil at
first after shorter intervals (e.g. monthly).
The test sample must be taken from the pressure line at operating temperature.
Regardless of the usage the hydraulic oil should be changed after one year at the latest. If the
oil is not changed or is changed too late the machine will be unreliable and damaged, especially
as a result of abrasive contaminants in the hydraulic oil which can not be removed by the filter.
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ATTENTION
Leaked oil is always contaminated and must never be put back into the hydraulic tank!
Ensure greatest cleanliness! The filler on the hydraulic tank and the filler and screw plugs on the
transport and storage tanks must be thoroughly cleaned before use. The new hydraulic oil must
be checked for ingress of water. If hydraulic oil becomes contaminated with water it will be of
inferior quality and must not be used any further.
The oil change should be carried out immediately after the end of a production run on the
machine. This ensures that the oil is at operating temperature and viscosity (45 °C to 50 °C /
113 °F to 122 °F) (with ServoPower (Option) 35°C and 40°C (95°F and 104°F)) and particles are
still in suspension so that they can be pumped out with the oil.
1 Clean the filler screws and the screw plugs on transport and storage containers.
2 Check the hydraulic oil grade; see "Oil quality"
3 Prefilter the hydraulic oil through a mobile filtration unit.
5 Switch off main isolator and secure against accidental reconnection.
6 Clean the area round the venting filter.
7 Unscrew the venting filter lock and remove the complete venting filter from the pipe
socket.
8 Empty hydraulic tank with a pump unit via the pipe socket. The hose must reach to the
bottom of the tank.
9 Remove the tank cover; clean the hydraulic tank
ATTENTION
If the tank is filled above the maximum level, hydraulic oil will come out of the venting
filter!
The new hydraulic oil may only be filled through the air venting filters. This must be done
through a separate filtration unit (filter mesh size 3 μm / 118.11 μinch), which guarantees a
cleanliness class of 15/12 acc. to ISO 4406 (Class 6 acc. to NAS 1638 or CETOP RP 70H)
Experience has shown that even new oil is not this clean.
ATTENTION
Only use new hydraulic oil and under no circumstances mix different grades or different
makes with each other. The type of oil should not be changed without compelling
reasons. If this is the case, the system must be flushed out with the new oil first!
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To avoid mixing oils it is recommended to mark the oil tank and fillers with the oil type.
1 Fill the hydraulic tank to the maximum mark with a mobile filtration unit
The max. filling level is shown by the upper marking on the oil level indicator.
2 Place the venting filter on the pipe socket again.
3 Reconnect the bypass filter unit, if fitted
ATTENTION
Before switching on the machine, the hydraulic oil should be allowed to stand for approx.
1 hour to let the air trapped during filling escape!
8.6.2 Deaeration
After filling the hydraulic tank air must be bled from the hydraulic system.
• Press the "Hydraulic start" key to switch on the hydraulics
• Press the "Setting" key.
• Drive the clamping platen, injection unit and injection cylinder several times to and fro
over their whole stroke.
Bleeding is carried out effectively when no foam appears in the hydraulic tank, movements are
smooth and there are no strange noises.
The oil level should be checked after bleeding and topped up if necessary. Care must be taken
to use the same oil type.
8.6.3 Checking the oil level

Continuous (daily) monitoring of the oil level is required as a drop in the oil level below the
marked minimum volume may lead to an increase in operating temperature, undissolved air and
pump failure from cavitation.
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8.6.4 Oil change Axial bearing
For injection unit 8800 only and if the "Servo-motor" option is installed
The oil should be changed every 5000 operating hours.
1 Turn off the main switch and secure against accidental reconnection.
2 Dismount the injection cylinder guarding (screw out the screws).
3 Thoroughly clean the area around the vented filler cap.
4 Undo the vented filler cap slightly to allow air to enter, do not unscrew entirely.
5 Undo fitting underneath and drain the gear oil into a suitable container.
6 Screw in the screw connection underneath.
7 Unscrew the vented filler cap (1).
8 Pour in new gear oil.
9 Screw in the vented filler cap (1).
10 Mount injection cylinder guarding.
ATTENTION
The oil level should be checked daily.
The axial bearing should be checked daily for leaks and damage to the shaft seals.
8.6.5 Hydraulic filter

Pressure filters are installed in front of components which require extra protection. The pressure
filter has a contamination indicator which sends an error message to the screen if it is triggered.
At the first possible pause in production (e.g. shift change) the filter must be replaced. If there
are no spare filters available one must be ordered immediately. The article number can be found
in the chapter "Spare parts / Plans".
In principle the filter element should be changed at the same time as the oil. If the above error
message or the oil analysis indicates an early oil change, then the oil filter should be changed
early too.
The greatest cleanliness must be maintained. The contamination indicator is suppressed at low
temperatures; i.e. if the oil temperature is below 27 °C (80.6 °F) the switch does not function.
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8.6.6 Changing the filter element
• Switch off the machine and wait for complete pressure loss.
Burning hazard if touched! At oil temperatures above 60 °C (140 °F) wear appropriate
PPE!
• Unscrew filter housing (1). Run hydraulic oil into a suitable container.
4
1
2
3
• Remove filter element (2); inspect the mesh surfaces for contamination and large
particles. These can be an indication of damaged hydraulic components.
• Dispose of filter element (2)
• Before fitting the filter element, check that the type designation is the same as that of the
filter element removed.
ATTENTION
Never clean or reuse a filter element!
• Replace the filter element. The filter element can not be cleaned. Any attempt to clean
the filter element can damage the filter material which will then allow contaminated oil to
reach the clean side of the filter element.
• Clean the filter housing (1) (inside) with a suitable agent (e.g. white spirit, paraffin/
kerosene) and make sure no dirt gets into the clean side.
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• Inspect the filter unit for mechanical damage, especially to sealing faces and seals.
Renew damaged parts. Check O-rings (3 + 4) and change if damaged.
ATTENTION
If damaged components are not replaced and if the filter is not kept in perfect condition,
other hydraulic components may be damaged or fail!
• Lightly oil the threads and sealing faces of the filter and the O-ring (3) of the filter element
(2) with clean liquid
• Mount the filter element on its location.
• Screw the filter housing (1) right in.
• Start the hydraulic system under pressure and check the filter for leaks. If a leak is found
then the corresponding O-ring should be renewed.
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8.6.7 Venting filter
Venting filters allow filtered air to pass in and out of the oil tank as the oil level changes. Its
effectiveness depends upon the environment, but it should be checked and if necessary the
element renewed after 2500 operating hours at the latest, paying the greatest attention to
cleanliness.
HM_1034.BMP
Change the venting filter hydraulic tank

• Switch off the machine and wait for complete pressure loss.
• Remove guarding if necessary.
• Remove hexagon nut (1) (DIN 934 M10 SW 17) and washer.
• Lift off cover (2)
• Remove element (3) and mount new element
• Put cover back on
• Put on washer and Skt. Screw on the nut
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8.6.8 Leaks
Observe any leaks in the hydraulic system and remedy them by resealing or tightening the
screw connections.
Damaged hydraulic hoses and hose assemblies must be renewed at once, please refer to the
chapter "Hose assemblies".
Regular checks of the hydraulic fittings, hose asemblies, cylinders, valves, pump(s) etc. must be
carried out every 160 running hours.
8.6.9 Oil cooler

Although the oil cooler may be considered maintenance free, it is recommended to give it some
preventive maintenance every 20,000 operating hours.
Contaminated water must be filtered and if scale is present the cooling lines must be descaled.
See also "Water quality".
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8.7 Pressure vessel
Before starting up the machine the nitrogen pressure within the pressure vessel (option) must
be checked. In case the nitrogen pressure falls short of the indicated value (see name plate or
hydraulic plan), nitrogen has to be refilled.
Pressure vessels are subject to the safety regulations applicable at the place of use. Before
starting up the machine, they have to be accepted by the technical standards organisation (e.g.
TÜV) responsible in the proprietor’s region.
The proprietor of pressure vessels is responsible for ensuring the proper condition, operation
and monitoring.
Neither welding nor soldering nor any mechanical processing may be performed on the
pressure vessels. Improper repairs can cause severe accidents and may only be carried out by
authorised customer service personnel.
8.7.1 Checking the nitrogen pressure

Check the nitrogen pressure before and during operation as follows:
1 At least once within the first 40 operating hours. Major losses in nitrogen will immediately
be detected and be compensated.
2 In case no losses have been detected during the first inspection, the next inspection is to
be carried out after 500 operating hours.
3 After this inspection further inspections may be carried out at an interval of 1000
operating hours.
ATTENTION
The nitrogen pressure changes temperature dependently. For this reason, inspections
should always be carried out under equal temperature conditions. After filling or
discharging nitrogen please wait 5 minutes approx. until the temperature has been
balanced. Check the nitrogen pressure afterwards!
During each check nitrogen will escape through the filling unit. This will reduce the
nitrogen pressure, especially in case of small pressure vessels!
The pressure within the mobile nitrogen cylinder (for filling the pressure vessel) may not
exceed the maximum permissible operating pressure of the machine’s pressure vessel
or the pressure gauge. Otherwise a pressure reducer has to be inserted between the
mobile pressure cylinder and the filler!
Please keep all certificates in a safe place!
When demanding certficates later on, please state the contents, the factory number and the
year of manufacture of the vessel. These data is embossed on both ends of the vessel.
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8.7.2 Replenishing, reducing and testing the nitrogen pressure
The filling and testing unit is not included in the standard delivery.
1 - Connection for the nitrogen cylin-

der (Right-hand thread W24.32x 1
1 2 3 1/4")
2 - Non-return valve (valve insert)
4 3 - Button
4 - Pressure pin
5 5 - Valve gate
6 - Venting valve
6 7 - Union nut
8 - Seal element
9 - Connection piece (SAE 7/8" -
7 14UNF -2B)
10 - Gas filling valve
8 11 - Bubble accumulator
9
10
11
1 Mount the pressure gauge as described in "Checking the hydraulic pressure".

2 Switch off the machine at the main switch.
3 Wait for the pressure of the hydraulic oil within the pressure vessel to be reduced (until
the pressure gauge indicates 0 bar / psi)
4 Unscrew the covering cap(s) of the gas filling valve.
5 Screw the filler unit to the gas filling valve.
6 Check whether the venting valve of the filler unit is closed.
7 Screw the hose assembly’s connecting piece to the nitrogen bottle.
8 Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly flowing
into the pressure vessel (for the filling pressure please refer to the hydraulic plan or the
respective label).
9 Close the shut-off valve after reaching the desired nitrogen pressure.
10 Use the venting valve to close the filling hose.
11 Press the button of the filler unit, release it and read off the nitrogen pressure at the
pressure gauge.
12 In case the nitrogen pressure is too high, carefully press the pressure pin after opening
the venting valve to reduce the pressure.
Steps 7, 8 and 9 will be omitted when reducing or checking the pressure.
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8.7.3 Checking the hydraulic pressure
• Screw a pressure gauge connection-hose assembly, which is not included in the standard
delivery, to the fitting of a pressure gauge.
• Clean the surroundings of the miniature measuring connection at the hydraulic block of
the pressure vessel.
• Remove the sealing cap of the miniature measuring connection.
• Screw in the fitting of the pressure gauge connection-hose assembly.
• You can only retrieve the hydraulic pressure within the pressure vessel from the pressure
gauge.
8.8 Hose assemblies

The safety regulations are laid down in DIN 20066 Parts 4 and 5 as well as in EN 201. They
contain regulations on the testing, replacement and storage of hydraulic hose assemblies.
The proprietor of the machine has a duty to ensure that hose assemblies are replaced at the
appropriate intervals, even if no technical shortcoming is apparent in the hose assembly.
8.8.1 Service life

Even when properly stored and under allowed stresses, hoses and hose assemblies are subject
to natural ageing. Their service life is therefore limited.
Improper storage, physical damage and non-approved application are the most common causes
of failure.
The service life (including storage time) for hoses and hose assemblies must not be exceeded.
The date of manufacture is permanently marked on every hose and hose assembly.
The hose assemblies have to be replaced after 20000 operating hours at the latest
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Hoses which have already been in service as part of a hose assembly may not be reused as
they no longer conform to the requirements of DIN 20066.
If a hose is reused, then the liability lies with the person who fits the hose assembly.
Only hose assemblies with swaged-on stand-pipe ends can be reused. The length of a hose
assembly is defined as shown in the following diagram.
Length including standpipe ends
8.8.2 Inspection criteria

The serviceability must be verified by a hydraulics expert every 1000 operating hours.
Hose assemblies must be replaced at once if any of the following criteria are established on
inspection:
• Damage to the outer sheath which reaches the reinforcement (e.g. chafing, cuts or
cracks).
• Embrittlement of the outer sheath (cracking of hose material).
• Deformation not consistent with the natural form of the hose assembly, in either the
pressurised or the relaxed condition, or in flexure, e.g. delamination or blistering (see also
DIN 20066 Part 4)
• Permeability or porosity.
• Damage or deformation of the hose fitting (affecting sealing); trivial surface damage is not
a reason for replacement.
• Movement of the hose from the ferrule.
• Corrosion of the fitting affecting function or strength.
• Assembly guidelines not followed (DIN 20066 Part 4).
• Storage or service periods elapsed.
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8.9 Hydraulic accessories
If the machine’s hydraulic system is equipped at the customer’s wish with additional
components, like bypass filtration units, then the corresponding operating instructions in the
"Accessories" section of this technical documentation must first be read, in its entirety, without
fail.
If the hydraulic system of the machine is not relieved of pressure before fitting or
removing hydraulic component it may empty explosively with the risk of damage and
injury!
Before operating the machine, its safety regulations and the operating instructions of the
hydraulic accessory in question must be observed without fail!
The mounting and dismounting, setting, commissioning and repair of hydraulic

accessories may only be carried out by authorised personnel!
8.10 Lubrication
8.10.1 Manual grease lubrication

Before greasing, the machine must be secured against accidental reconnection!
The lubricating nipples should be treated every 500 operating hours with an ordinary
grease gun (may be pneumatic) for DIN 71412 - type lubricating nipples.
The grade of grease can be seen in the "Hydraulic oil and lubricant table".
8.10.2 Three phase motor

The three-phase motor bearings have to be cleaned and regreased every 20000 running hours.
The grade of grease can be seen in the "Hydraulic oil and lubricant table".
8.10.3 Screw drive
Before checking, the machine must be secured against accidental reconnection!
The axial bearing is arranged so that the leakage line from the hydraulic motor lubricates it. No
maintenance is thus necessary in this case.
The oil level must be checked before the first start-up and, if necessary, oil must be filled in or
refilled in the "Axial bearing" of injection unit 8800 and if the servo-motor option is installed, refer
to paragraph 8.6.4.
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8.10.4 Corrosion protection
All bare parts (tie-bars, piston rods, guide rails), where no movement takes place should be
sprayed every 500 operating hours with a corrosion inhibiting oil.
8.11 Water system
ATTENTION
When using water piping note the corrosion stability of metallic materials against water
in accordance with DIN 50930!
Water piping and the respective fittings are to be weekly checked for corrosion and leakages by
a skilled technician.
Burning hazard if touched! At water temperatures above 50 °C (50.00°C) wear appropriate

PPE!
8.11.1 Water quality

If there are deviations from the following guidelines, please contact our technical customer
service or one of our subsidiaries. The addresses can be found in the "Customer service"
chapter.
pH value: 6,5 - 9
Water hardness: < 1,8 mmol / l (681 ppm / gal)
Solids: < 0,03 ‰ (30 ppm)
Filter mesh: < 100 μm (0.004 inch)
In the relation of solids content to water hardness, it should be noted that the harder the cooling
water is the lower the solids content has to be. If the level of suspended matter is over 0,03 ‰
(30 ppm), a water filter with a mesh size < 100 μm (0.004 inch) must be fitted before the water
system.
8.11.2 Closed cooling circuit system

It is recommended to add a corrosion inhibitor to the cooling water (e.g. Ferrophos 8579 from
Henkel).
We recommend ethylene glycol type 420 as an antifreeze (60 % water and 40 % ethylene
glycol). This is suitable for a temperature range down to -30 °C (-22 °F) and is also a corrosion
inhibitor.
SM1GB0SA
8.11.3 Hydraulic oil temperature
Check the hydraulic oil temperature in the oil tank daily. The machine is most efficient at an oil
temperature between 45 °C and 50 °C (113 °F and 122 °F) (with ServoPower (Option) 35°C and
40°C (95°F and 104°F)(.
The current hydraulic oil temperature will be displayed on the screen (B2 = in the actual
value field "T12" on page 2 of the "Temperature control zones" screen page / B4 = "Barrel
temperatures 1" screen page).
8.11.4 Oil cooler

Every 20000 running hours, the cooling tubes should be flushed out with a descaling solution to
remove any limescale deposits (max. 16 bar / 232 psi).
8.11.5 Cooling water flow governor

• Check cooling water flow governor daily for flow and leaks.
• Likewise check the cooling water connections and hoses for flow (no kinked hoses) and
leaks.
• The sight glasses may need cleaning if the coolant is dirty.
• The consumers, moulds, throat cooling, etc. should be flushed out every 20000 operating
hours with a descaling solution.
SM1GB0SA
For all work involving fitting, removal, modification and maintenance, the legal rules and
regulations and the safety instructions in the "Safety" chapter must be observed without
fail!
Work on electrical components may only be carried out by a qualified electrician!
8.12.1 Filter mats

The filter mats can be cleaned as follows:
• Washing in water (up to approx. 40 °C / 104 °F, with mild detergent if desired). Shaking,
vacuuming or blowing out with air is also possible.
• If the dust is greasy the filter mat must be washed out in water with a grease dispersant
additive.
8.12.2 Buffer battery

The control unit is protected from data loss by a buffer battery. When the error message "Buffer
battery flat" appears, the battery has to be replaced. The battery must be replaced for the first
time after 5 years at the latest, then every 3 years.
Battery change (type: lithium battery 3 V / 950 mA):
ATTENTION
Data loss without buffering! For security purposes, a copy of the service and tool record
has to be filed on floppy disk before changing the battery.
1 Switch off the main switch.

After changing the battery, the main switch has to be switched on again within 30 sec. so
that no data are lost
2 Carry out an electrostatic discharge at the top hat rail or at the earth connection (do not
reach into the power supply)
3 Open the battery compartment by means of a screw driver. Position the screw driver in
the slot and open the compartment by lifting
4 Pull the battery out of the support by pulling at the battery compartment cover
SM1GB0SA
5 Take out the lithium battery (do not touch the battery with pliers or uninsulated tweezers
-> short circuit). Only touch the battery on the front side with your hands. Insulated
tweezers can also be used to take out the battery.
6 Position the new battery with the correct polarity. The removal strip must be located
underneath the battery, otherwise the battery cannot be extracted
7 Close the cover of the lithium battery

8 Switch on the main switch
When disposing of batteries, the legal requirements must be met. The proprietor of the
machine is responsible for proper disposal!
SM1GB0SA
8.13 Pneumatic system
If the pneumatic system is not relieved of all pressure before work starts, there is a risk
of explosive emptying with possible damage or injury!
8.13.1 UNIFEED material feeder
1
2
3
4
The secondary filter (3) of UNIFEED material feeder (option) should be cleaned as necessary
and in any case inspected at least once a week, depending on the amount of dust. Its service
life is limited and it should be renewed at the first sign of loose fibres (by simply removing it from
its holder).
The primary filter (2) is automatically cleaned by compressed air after every conveying cycle. If
it becomes clogged it is cleaned as follows:
1 Turn off air supply.
2 Remove knurled nuts (4).
3 Lift off cover (1).
4 Clean and insert primary filter (2) again.
5 Insert cover.
6 Do up knurled nuts (4).
When fitting the filter care must be taken to position the filter O-ring properly in the groove
provided.
SM1GB0SA
The oil level of the air supply unit (option) should be checked every 8 operating hours and
topped up if necessary. The oil grade is given in the "Hydraulic oils and lubricants table".
8.13.3 Filter cartridge

The interval for cleaning depends on the amount of dirt in the air. An interval of 500 running
hours may be taken as a guide.
• Turn off air supply.
• Unscrew filter cartridge.
8.13.4 Mechanical scotch

The mechanical scotch (option) will only work if all components are in faultless condition and
moving parts have free movement. Care must be taken that the face of the scotch (or "flag"),
against which a tooth of the scotch-bar presses when it is activated, shows no significant wear.
Malfunction of the mechanical scotch can be avoided if the hardened plate is turned over or
renewed in good time.
SM1GB0SA
9 Spare parts / Plans
The chapter Spares / Plans contains parts list, plans and drawings representing the complete
range of the machine, broken down into assemblies. There is an assembly drawing for every
sub-assembly. Each spare part can be found here listed under a position number.
In order to avoid misunderstandings, it is necessary to give the Machine Number with every
spare parts order. In addition please state the Identification number (ID No.), the Designation
and the desired Quantity.
When ordering, please contact the Wittmann Battenfeld GmbH agency responsible for you or
contact Wittmann Battenfeld GmbH directly.
EWAGB0TB
Chapter 9 - 1
0814TW
EWAGB0TB
10 Special descriptions
EWAGB0UB
Chapter 10 - 1
0814TW
EWAGB0UB

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O P E R AT I N G I N S T R U C T I O N S

PRODUCT LINE SmartPower B6

Read before using the injection moulding ma-

Wittmann Battenfeld GmbH

Subject to technical changes without prior notice.

Production line SmartPower

Machine model xxx / xxxx

Control system type UNILOG B6x

Machine number 135xxx-100

Year of manufacture 2014

Number of instruction manual SM1GBV00_0115

Date of issue 14.01.2015

2.1................................................................................................................................................ Safety regulations

3...................................................................................................... Technical data

3.1............................................................................................................................................. General information

4.1............................................................................................................................................. General information

5................................................................................................... Mould mounting

5.1 ......................................................................................................................................................... Preparation

6..........................................................................................Structure and function

6.1....................................................................................................................................................... Clamping unit

7.1............................................................................................................................................. General information

10........................................................................................... Special descriptions

.................................................................................................. Customer Service

1.2 Area of Applicability

1.5 Certificate of Conformity

1.6 Commissioning protocol

2.1 Safety regulations

Not for hand-held electrical

Case Hazard Consequence Measures *)

Reasonably foreseeable faults in installation and electrical connection

Case Hazard Consequence Measures *)

3.1 General information

3.2 Hydraulic equipment

3.3 Electrical equipment

3.4 Water system

Pump capacity (litres) 35 50 60 80 95

Power kW 7.5 11 15 18.5 22

2) according to WITTMANN BATTENFELD standard

2) according to WITTMANN BATTENFELD standard

2) according to WITTMANN BATTENFELD standard

2) according to WITTMANN BATTENFELD standard

Clamping force kN 250 350

Clamping force kN 500 600

Clamping force kN 800 900

Clamping force kN 1100 1200

3.8 Mould dimensions

Material Factor Material Factor

ABS 0.88 PP + 40 % Talcum 0.98

3.10 Weights of screws and barrels

Injection unit Screw diameter Weight

Tightening torque Assembly

High temperature heater bands

4.1 General information

4.2 Unpacking / storage

The machine is packed as standard to withstand transportation without damage. However it

4.4 Space requirement plan

This machine is equipped with a transport monitoring system.

Crane transport with one lifting gear.

SmartPower machine weight

Adjustment of the oscillating elements

Type Height Setting range SmartPower 25 - 120

Oscillating element Ø 160/M16 59 mm [2.32 inch] 30 mm [1.18 inch] 8

SmartPower safety gate