Battenfeld PLUS 250/50 User manual

Manual
Injection moulding machine PLUS
Type of machine: PLUS 250/50
Control system: UNILOG 1020
Machine number: 114899-100
Year of manufacture: 1993
Version: PL120102 06/93
Austria

Battenfeld Kunststoffmaschinen Gesellschaft m.b.H.
Wr.Neustädter Straße 81 • 2542 Kottingbrunn • Austria
Tel. [phone] • Fax [phone]
[e-mail]
www.battenfeld-imt.com
DIN EN ISO 9001
Injection MoldingInjection Molding
Injection MoldingInjection Molding
Injection Molding

Table of Contents
A: PL120100.IN1
B: PL120100.IN1
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß
Chapter: INH
Page: 1
1 General
General instructions for this Battenfeld machine.
2 Safety
This chapter has to be read and understood by each employee
who has contact with the machine.
3 Technical Data
Contains technical data, installation plans and platen
drawings.
4 Transport - Siting
Important details relating to the transport, siting and startup
of the Battenfeld machine.
5 Structure and Function
Structure and function of each individual build group and user
manual for the control.
6 Operation
All important details for user operation of the Battenfeld
machine.
?UNILOG

Table of Contents
A: PL120100.IN1
B: PL120100.IN1
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß
Chapter: INH
Page: 2
Dieser Text dient
nur als Hinter-
grund. Das Kapitel
Stichwortverzeich-
nis und Glossar
zeigt Ihnen die ent-
sprechenden Sei-
ten im Text auf und
ver-
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C
B
7 Maintenance
Alldetailsfor servicing,maintenanceand fault-finding.
8 Spare parts / Drawings
Detaileddescriptionandsparepartslistsaswellashydraulic
and electrical drawings displaying existing parts.
9 Service
Contact addresses of all service partners.
10 Index
Explanation of the most important machine-related terms.
11
Additional chapter for special modules.
12 Accessories
Technical documentation of details and build groups of
suppliers.

Table of Contents
A:PL120101.IN2
B:PL120100.IN2
E: 03.93 / T. Weiß
G: 05.94 / G. Krajnik
Chapter: INH
Page: 3
1 General
1.1 Introduction
1.2 Area of application
1.3 Explanation of symbols
1.4 Copyright
1.5 Statement of delivery
2 Safety
2.1 Safety regulations
2.2 Alarm signs
2.3 General drawing
2.4 Electrical access protection
2.5 Hydraulic access protection
2.6 Mechanical access protection
2.7 Guarding
2.8 Safety device for handling unit
2.9 Safety device supervision
3 Technical Data
3.1 Dimensions of machine
3.2 Rating
3.3 Diagram / Injection pressure
3.4 Diagram / Injection velocity
3.5 Diagram / Injection volume
3.6 Diagram / Injection stroke
3.7 Diagram / Screw speed
3.8 Diagram / Closing pressure
3.9 Diagram / Closing velocity
3.10 Diagram / Closing stroke
3.11 Fitting dimensions of machine
3.12 Dimensions of mould
4 Transport - Siting
4.1 Spatial requirement plan
4.2 Transport of machine
4.3 Siting of machine
4.4 Oil filling
4.5 Table of hydraulic oils and lubricants
4.6 Connection to cooling water distributor
4.7 Oil cooler fitting
4.8 Connection to power line
4.9 Corrosion protection
4.10 Storage

Table of Contents
A:PL120101.IN2
B:PL120100.IN2
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G: 05.94 / G. Krajnik
Chapter: INH
Page: 4
?
5 Structure and Function
5.1 Overview of build groups
5.2 Closing unit
5.2.1 Technical description
5.2.2 Mould fitting
5.2.3 Instructionsfor fitting -adjustment offitting height
5.3 Injection unit
5.3.1 Technical description
5.3.2 Nozzle change
5.3.3 Instructions for setting - nozzle centre
5.3.4 Change and prestressing of synchronous belt
5.3.5 Screw change and screw cylinder change
5.4 Hydraulic unit
5.4.1 Pump element
5.4.2 Oil tank
5.4.3 Oil filter
5.4.4 Electrical oil filter clogging display (optional)
5.4.5 Oil cooler
5.4.6 Supervision and indication device
5.4.7 Variable capacity pump setting
5.4.8 Relief valve amplifier
5.4.9 Velocity selection of relief valve amplifier
5.4.10 Pressure selection of relief valve amplifier
5.4.11 Setting for maximum pressure protection for
variable capacity pump
5.4.12 Hydraulic oil preheating
5.4.13 Hydraulic core pull (optional)
5.4.14 Hydraulic screw-off device (optional)
5.5 Pneumatic unit
5.5.1 Material feeder device UNIFEED (optional)
5.5.2 Pneumatic core pull
5.6. Electric unit
5.6.1 Electric drive
5.6.2 Control box
5.7 Control
5.7.1 Description of electronic system
5.7.2 UNILOG user manual
UNILOG
1020

Table of Contents
A:PL120101.IN2
B:PL120100.IN2
E: 03.93 / T. Weiß
G: 05.94 / G. Krajnik
Chapter: INH
Page: 5
6 Operation
6.1 Startup
6.2 Starting the machine after Emergency Stop
6.3 Machine shutoff
7 Maintenance
7.1 General
7.2 Maintenance schedule
7.3 Table of hydraulics and lubricants
8 Spare Parts / Drawings
8.1 Guidelines for ordering spare parts
8.2 Basic machine data
8.3 Closing component
8.3.020 Accessories for machine frame
8.3.025 Photoelectric safety device (optional)
8.3.072 Closing platen support
8.3.080 Closing cylinder
8.3.140 Mechanical closing protection (optional)
8.3.150 Ejector coupling
8.3.170 Hydraulic screw-off device (optional)
8.3.220 Protecting guard for closing unit
8.4 Injection component
8.4.294 Unit for nozzle drive and nozzle movement
8.4.330 Complete nozzle unit
8.4.330 Heater band for screw cylinder
8.4.330 Screw cylinder
8.4.360 Cylinder cover
8.4.362 Sheathing of injection unit
8.4.380 Hopper for granulated moulding material
8.5 Hydraulic system
8.5.1 Drawing of hydraulic system
8.5.2 List of hydraulic components
8.6 Electrical installation
8.6.1 Drawing of electrical installation
8.6.2 List of electrical components

Table of Contents
A:PL120101.IN2
B:PL120100.IN2
E: 03.93 / T. Weiß
G: 05.94 / G. Krajnik
Chapter: INH
Page: 6
8.7 Pneumatic system
8.7.380 Material feeder device UNIFEED (optional)
8.7.700 Pneumatic core pull
9 Service
10 Index
10.1 Description of technical terms
10.2 Index
11
12 Accessories
Dieser Text dient nur
als Hintergrund. Das
Kapitel Stichwortver-
zeichnis und Glossar
zeigt Ihnen die ent-
sprechenden Seiten
im Text auf und ver-
A
C
B

General
A: PL120100.010
B: PL120100.010
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß
Chapter: 1
Page: 1
Chapter 1: General
1.1 Introduction
This user manual has been written specifically for the
personnel in charge of this Battenfeld product moulding
machine and should be read, understood and precisely
followed by them.
The complete technical documentation should always be
kept close by the machine; it should be accessible to the
operating and maintenance personnel at all times.
It is only through closely following this manual, in particular
chapter 2 “Safety”, that hitches in the operation of the
machine can be avoided, and smooth functioning will be
guaranteed. For this reason, it is essential to make this
manualavailabletothecompetentpersonnel.Thisshouldbe
done before the startup of the machine since we accept no
liability for any defect or breakdown of the machine arising
out of the ignorance of this manual on the part of the
corresponding personnel!
Thereexiststhepossibilitytohaveyourpersonneltrainedby
us,eitheratourplantoratyours.PleasecontactourTraining
Department for further details.
Inthecasethatdifficultiesshouldoccurinspiteoftheabove,
pleasecontactourServiceDepartmentoroneofourlicensed
representatives (addresses in chapter 9 “Service”) who will
be glad to be of assistance.
This user manual applies only to machines commissioned
according to chapter 3 “Technical Data”.
With respect to the information and data given in this user
manual, we reserve the right to any technical modifications
thatmaybecomenecessaryinordertoimprovethisinjection
moulding machine.

General
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Page: 2
Safety
ATTENTION!
Voltage
1.2 Area of application
The injection moulding machines of the PLUS series were
conceived for the processing of thermoplastics, thermosets
and elastomers as well as for LIM.
Applications going beyond this definition do not conform to
the original intended use of the machine. The manufacturer
acceptsnoliabilityfordefectsarisingfromthistypeofmisuse
- the risk is borne solely by the operator.
1.3 Explanation of symbols
The safety symbol is featured in all instructions for work
safety contained in the present manual that refer to possible
hazards to human life and health. Please observe these
instructions and proceed with the utmost caution.
Communicate all instructions for work safety to other users
as well. Apart from the instructions contained in this user
manual,itisalsonecessarytoobservethegeneralinstructions
for safety and prevention of accidents.
This Attention! sign appears wherever it is especially
important to comply with guidelines, instructions and
indications, and to observe the correct operation of routines
and machine cycles as precisely as possible, and wherever
it is vital to avoid any damage to, or destruction of, the
machine and/or other elements of the installation.
The voltage symbol concerns all passages in the manual
which refer to the staff coming into contact with electrical
installations and equipment. Please always observe the
localregulationsinforcewithrespecttothesafetyofelectrical
installations.
The symbol for environmental hazards refers, inter alia, to
the environmental hazards posed by the disposal of various
materials. When carrying out repair and maintenance work,
please take care that such wastes are properly disposed of.
Environmental
hazards

General
A: PL120100.010
B: PL120100.010
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G: 06.93 / T. Weiß
Chapter: 1
Page: 3
1.4 Copyright
The copyright for this user manual rests with Battenfeld
Ges.m.b.H. This user manual is destined for the staff in
chargeofthefitting,operationandsupervisionofthismachine.
The technical instructions and drawings contained in it may
notbecopied,disseminated,commercializedforcompetitive
purposes or communicated to third parties without
authorization by Battenfeld.
1.5 Statement of delivery
The purpose of the statement of delivery enclosed in this
usermanualistodocumentthehanding-overofthemachine
and to ensure the completeness of the user manual. After
verification, please fill in and sign the statement of delivery,
and return it to the “Documentation” department.

General
A: PL120100.010
B: PL120100.010
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Chapter: 1
Page: 4
(1) Type of machine
(2) Address of customer
(3) The machine specified in item (1) above was acquired by us.
Together with the machine, (number)
user manual(s) was/were handed over to us.
Statement of Delivery
ensuring the delivery of the Technical Documentation
to the end customer
Number of machine
(4) Date of delivery
Date
Signatureof customer servicespecialist
Companystamp/Signature
Companystamp/Signtureifnotidenticalto(5)
Signatureofcustomer Date
Telefaxtransmission
To: Documentation Department (0)2252 404-402
From:
(5) Address of authorized dealer or importer.
(6)Themachinewasdeliveredtothecustomer
in accordance with the manufacturer’s
specifications.
01

Safety
A:PL120100.020
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G: 06.93 / T. Weiß
Chapter: 2
Page: 1
Chapter 2: Safety
2.1 Safety regulations
Numerous safety devices of the injection moulding machine
and the robot contribute to its operational safety and the
prevention of accidents. The operator is responsible for the
smooth functioning of the safety devices.
This injection moulding machine has been designed and
builtinkeepingwiththecurrentlyvalidregulationsfortechnical
safety according to European Standard EN 201 and is
operationally reliable. However, hazards may arise if this
machine is either misused by personnel not specifically
trained to handle it or is used for other than its intended
purposes.
For reasons of safety, all unauthorized modifications or
changes of the machineand the robot are prohibited and
require Battenfeld’s approval.
Whenprocessingsyntheticmaterialsthatcausetheemission
of gases, dust or steam hazardous to human health, the
operator of the machine must ensure that appropriate
ventilation is provided for the protection of the operating
personnel.
All persons in charge of the siting, startup, operation,
maintenance and repair of the machine or a robot in the
enterpriseoftheusermustfirsthavereadandunderstoodthe
user manual and in particular the “Safety” chapter. This
manualmustatalltimesbeaccessibletotheabovementioned
personnel. The head of the workshop, the shift foreman or
any other staff members responsible for the operational
safety of the machine must be immediately notified of all
extraordinary occurrences regarding the machineand the
robot.Undercertaincircumstances,itmaybecomenecessary
to switch off the machine immediately using the Emergency
Stop switch and the master switch.
Any process impairing the operational safety of the machine
is to be avoided.

Safety
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The operating enterprise shall ensure that no unauthorized
persons on the installation will handle the machine. The
machine may be operated only by persons
- over 18 years of age;
- with of the necessary technical knowledge;
- to be expected to comply with their task in a reliable
and sensible manner.
Theoperatingenterpriseshallemployappropriateinstructions
and checks to safeguard that the work area around the
installationiscleanandtidy.Allcomponents,inparticularthe
safetydevices,shallbesubjecttoregularcheckupstoensure
perfect operating conditions. The operating personnel shall
continuouslycheckthemachineandtheworkarea,especially
if a robot is used, with respect to possible hazards and
eliminatetheseIMMEDIATELY,interruptingtheoperationof
the machine until this has been achieved.
All warning and safety devices of the installation shall be
complied with.
For the operation of the machine and the robot, the local
provisions for work safety and the prevention of accidents
apply unconditionally. It is principally prohibited to remove,
modify or put out of operation any of the safety devices. If
siting,repairormaintenanceworkshouldrequiretheremoval
of a safety device, this safety device shall be re-installed
immediately after the completion of the maintenance and
repair work.
When working on the machine and the robot, it is principally
requiredtoswitchoffthemasterswitchandprotectitagainst
unauthorized reactivation. All components, in particular the
safetydevices,shallbecheckedregularlytoensurethatthey
are in perfect working condition. After electrical fitting and
repair works have been carried out, the installed safety
devices (e.g. earthing resistance) must be rechecked.

Safety
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2.2 Alarm signs
Before putting the installation into operation,
always read and familiarize youself with the
operating manual, especially chapter 2 “SAFETY”!
DANGER OF INJURY!
The machine must not be put into operation
if the protective guard has been removed!
WARNING! HIGH VOLTAGE!
Do not activate the master switch if the
control box is open!
WARNING!
Only fill the tank with clean hydraulic oil, purity
class 15/12 in keeping with ISO standard 4406!
WARNING!
Check the hydraulic filter daily for clogging. If
the filter is exchanged, only replace
with original filter elements!
WARNING!
Check oil level daily!
WARNING!
Lubricate the grease lubrication
nipple every 2,500 working hours!
WARNING! HOT!
Do not touch the screw cylinder
of the injection unit!
ENVIRONMENTAL HAZARD!
Dispose of waste oil in accordance
with national regulations!

Safety
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Page: 4
2.6
2.42.5
Bild:Pl-0001.TIF
Bild:Pl-0002.TIF Bild:Pl-0004.TIF
2.3 General drawing

Safety
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Bild:Pl-0004.TIF
Pos 2
Pos 1
2.4 Electrical access protection
The various positions of the protective guard are monitored
by means of two guided switches safeguarding the position
of the guard.
Position - Protective guard closed;
Position switch 1 (S 24) actuated.
Position switch 2 (S 25) not actuated.
Position - Protective guard open;
Position switch 1 (S 24) not actuated.
Position switch 2 (S 25) actuated.
All other positions trigger the “Protective guard monitoring”
device which in its turn deactivates the hydraulic drive.
If the protective guard is open, the output signals of all
machine movements as well as the valve circuits of the
closing unit are interrupted.

Safety
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Bild:Pl-0002.TIF
Protective guard monitoring device
This device monitors the correct functioning of the following
elements:
a) Alternating operation of position switches (S 24, S 25)
b) Limit switch of hydraulic access protection (S 34).
c) Guided auxiliary contactors (K 288, K 289) in the valve
circuits of the closing unit.
Ifanerrorisidentifiedintheaboveelements,anerrormessage
“Protective guard” is visualized on the display.
2.5 Hydraulic access protection
If the protective guard is open, a mechanically actuated
distributingvalvewillpreventanymovementofthemachine.
If the distributing valve is actuated, the entire oil flow is
interrupted,andthecontentsofthecylindersareemptiedinto
the tank. The position of the valve is monitored by means of
a limit switch that is activated when the protecting guard is
opened.Moreover,this limitswitchalso interruptsall electric
output signals.