HAITAI HTW200 User manual

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Preface
Thank you very much for you purchase of the HAITAI Injection Machine.
The injection machine is good in capacity, superb in workmanship, and easy to operate.
The inside five point toggle clamp unit has many patent technology of our company, which enable the
machine to have a rigid structure and to be difficult to deform, other feature like force symmetry, smooth
movement, low noise. The uses of hollow spherical structure of the fixed platen design increase the
precision of the products. The flexible tie bar and nut to make sure that the tie bar free from fracture. The
widening space of open stroke and tension bar, therefore the use of the scope has been further improved.
The twin toggles of clamp structure that is five points arranged slanting is patent technique of our
company. The clamp unit is good in rigidity, no distortion, symmetry in force, less in noise and steady to
run. The fixed platen is designed hollow
The double balanced injection unit has stable performance and rigid structure. The low-speed-high
torque motor direct drives plasticizing. The capacity of plasticizing has been improved with a high
efficiency. The patent technology of double injection unit save the energy and increase the injection speed.
The use of high, medium and low-pressure screw is able to meet the thick-walled, thin-walled products
molding requirement.
The heat resistance type heated ring is PID controlled by computer. It features as heating fast, stable
temperature, the sensitive and accurate temperature conversion.
The "Mechanical - Electrical - Hydraulic" safety device ensure safe and reliable. The machine has a
reasonable layout and beautiful appearance. It can be easily operated and maintained.
The speed of opening/closing mold, change of pressure, the amount of pre-plasticizing, the switch
point from injection to holding, and the multi stage of injection is controlled by computer and the
movement is finished by the hydraulic system. These features result in a high precision, fast response,
integration of "mechanical –electric-hydraulic‖ advanced control systems.
The hydraulic system incorporates proportional pressure control; the main components are
international brand-name products.

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Please notice follow as:
★It is necessary of operation the machine correctly that you need to know function, feature and
maintenance of each part of machine.
★This operation manual provides to help you operate varies kind of injection machines made in our
factory.
★It is important for operator and worker to install and operate the machine.
★Please read this instruction carefully after the machine is put into operation. Then
provide proper handling and careful maintenance.
It is remember that safety team in the ―safety warning‖page in order to avoid danger of person
and machine by fault.
★Please notice safety direction
到Note: --Pay special attention
Attention: --Safety direction
The company will keep the machines to improve. This information may be different from some small
part of the machine. Please contact our company for the difference.
This information is a permanent paper for machines, please keep in good condition. The transfer of
machinery, together with the transfer of the operation manual at the same time is necessary.
The copy and backup, including excerpts of this manual is permitted without our consent. To show the
manual to a third party or copy is not allowed, we will have the right of action. We are nor responsible
for all kinds of information derived from this manual.
同时转让。

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SAFETYWARNING
The machine must be grounded.
Each switch button on the face board of controller must be at correct position
before starting machine. Do not touch live electricity parts after starting
machine.
Check main cable often, if cover of main cable has expose, broken and
dehisced, must be changed.
To ensure switch off power supply of machine when you maintain.
Grounding
To sure ground terminal of main electrical box connect with grounding cable
lie hidden in the earth.
The resistance of grounding cable must fit requirement specified, and the
ground cable must be laid as requirement specified.
Check grounding cable and grounding terminal often to make sure the
machine keep grounding well.
Fire danger no close oil tank!
Be caring for firing when cleans the oil tank by gasoline,
otherwise, it should occur dangerous to you or detonate the
machine.
Do not fire before the gasoline have not emanated completely as
finished clean.
You must be attention not to fire after open machine’s package,
because the oil tank of machine has cleaned by gasoline before
the machine leave the factory.
Do not allow changing or removing the safety devices
The safety devices equipped in the machine are good help you or your
conducts made.
The machine should be operated at normal state and safety devices work well.

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Do not allow changing or removing or the safety devices, but our company is irresponsible for in
case of fault of machine in accident.
You must operate the machine only at operation area; never allow operation other any place
(especially rear safety gate).
If the safety devices are not set to normal state, please inform our company by
telephone in time.
Contract –Telephone Number
Department
Telephone /Fax
Email
International trade dep.
Tel: [phone]
Tel: [phone]
Fax:[phone]
[e-mail]
Technical Dep.
Tel: [phone]
Fax:[phone]
[e-mail]
Service dep.
Tel: [phone]
Fax:[phone]
[e-mail]
Address: Haitai Industry Park Bai Zhang East Road, Ningbo City
Postcode：315101
Email：[email protected] [email protected]
Http：www.china-haitai.com

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CONTENT
1. Technical parameter
1.1 Main parameter 1-1
1.2 Structure of machine 1-2
1.3 Working principle 1-4
1.4 Clamp installation dimension 1-5
1.5 Preparation before purchase 1-7
2. Machine installation
2.1 Preparation before installation 2-1
2.2 Lifting machine 2-2
2.3 Installation and commissioning 2-4
2.4 Hydraulic oil 2-6
2.5 Cooling system 2-7
2.6 Electric wiring 2-9
2.7 Commissioning 2-12
2.8 Pump rotating direction testing 2-15
2.9 Preparation before trail operation 2-15
2.10 Check and adjustment 2-16
3. Safety
3.1 Four safety caution 3-1
3.2 Manningand environment management 3-1
3.3 Machine main safety Caution 3-2
3.4 Electricity safety equipment 3-9
3.5 Mechanical safety equipment 3-12

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3.6 Hydraulic safety devices 3-13
3.7 Safety operation 3-14
3.8 Poisonous gas, fog and powder 3-16
3.9 Quickly decomposed plastic 3-17
3-10 Machine’s noise grade 3-17
3-11 Cautions 3-17
4. Starting Operation
4.1 Check 4-1
4.2 Electricity voltage 4-1
4.3 Hydraulic oil pre-heating 4-2
4.4 Hydraulic system oil monitoring 4-2
4.5 Electricity-thermal starting 4-2
4.6 Manual operations 4-2
4.7 Semi-automatic operations 4-2
4.8Automatic operations 4-2
4.9 Description some activations of machine 4-2
4.10 Mounting and dismounting of mold 4-3
4.11 Adjustment of slide plate 4-7
4.12 Injection working step 4-8
4.13 Treating after finishing the injection 4-9
4.14 Replacement of barrel and screw 4-9
4.15 Replacement of plastic material 4-12
4-16 Selection and replacement of injection nozzle 4-12
4.17 Selection of screw and barrel 4-14
4.18Ajustment of backpressure 4-14
4-19 Maximum allowable temperature of plastic injection unit 4-14

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5. Machine maintenance
5.1 Lubrication 5-1
5.2 Maintenance of hydraulic unit 5-2
5.3 Cleaning of the barrel and screw 5-6
5.4 Daily maintenance 5-10
5.5 Cleaning 5-11
6. Accessaries
6.1 Clamping unit 6-1
6.2 Injection unit 6-5
6.3 Screw 6-8
7 Annex
7.1 Hydraulic system 7-1
7.2 Valve block 7-4
7.3 Electricity system 7-9
8. Injection parameter of thermoplastic plastics 8-1
9. Causes and trouble shootings for some injection molding defects
9.1 Clamping unit 9-1
9.2 Injection unit 9-2
9.3 Hydraulic and electricity units 9-5

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Chapter 1 Technical parameter and structure
1.1 Main parameter table HTW200
TECHNICAL PARAMETER TABLE
A
B
C
INJECTION
UNIT
SCREW DIAMETER
mm
45
50
55
SCREW L/D RATIO
L/D
23.3
21
19.1
SHOT VOLUME (THEORETICAL)
cm3
340
420
510
INJECTION WEIGHT
g
310
383
466
INJECTION RATE
g/s
124
154
186
PLASTICIZING CAPACITY
g/s
20.8
24.4
28.2
INJECTION PRESSURE
MPa
207
168
139
SCREW SPEED
rpm
155
CLAMPING
UNIT
CLAMP FORCE
KN
2000
OPEN STROKE
mm
475
SPACE BWTWEEN TIE BARS (W×H)
mm
530*530
MAX. MOULD HEIGHT
mm
530
MIN. MOULD HEIGHT
mm
200
EJECTOR STROKE
mm
140
EJECTOR FORCE
KN
70
OTHERS
MAX. PUMP PRESSURE
MPa
16
PUMP MOTOR POWER
KW
18.5
HEATING POWER
KW
13.6
MACHINE DIMENSION (L×W×H)
m
5.22×1.57×2.21
MACHINE WEIGHT
t
7
1.2 Structure of machine

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The injection machine is made of five units that are clamping unit, injection unit, hydraulic
system, electricity unit and machine body.
See Fig.1-1. and main parts of each unit see Fig.1-2.
Fig. 1-1
Electricity unit
Machine body
Clamping unit
Injection unit
Hydraulic system

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Fig.1-2
1.3 Working principle
The injection machine is controlled to run by special computer and each action is driven by
hydraulic. The machine can be worked by ―manually‖, ―semi automatically‖or
1. Clamping cylinder 2. Fixed platen 3. Clamping structure 4. Moving platen
5. Eject cylinder 6. Tie bars 7. Fixed platen 8. insurance bar 9. Carriage cylinder 10. Screw 11. Barrel
12. Hopper 13. Injection cylinder 14. Electricity box 15. Air circuit breaker 16. Machine body

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―automatically‖operation through hydraulic and electric control.
Manual operation:
The machine is manually operated.
Semi automatic operation:
Each action of the process is done automatically according to the specified program until a
cycle finished after closing the safety door.
Automatic operation:
The computer controls the machine action program; each action of process is automatically
done in cycle.
Automatic operation has two kinds of sensor full-auto and timing automatically.
Caution:
The machine shall be checked to ensure the safety devices
works well before manual or semi-automatic operation.
During an operating cycle:
Working process of the Injection Unit:
Plastics go into the barrel from the hopper;
The screw turns and the plastics are kneaded and extruded, producing and heating, which,
together with the externally barrel, melts plastics;
The melted plastics accumulated at front end of screw and driving screw backwards until
there is a certain amount of melted plastics;
The injection cylinder pushes the screw forwards and injects the melts plastics at the front
end of screw into the mould.
Working process of the Clamping Unit:
Driven by the clamping cylinder, the moving platen moves forward rapidly,
The moving platen slows down to clamp with high pressure when it is close to the mould,
Injection and cooling,
Mould open slowly,
Open mould to the required position.
Injection and clamping are done alternately to constitute an operating cycle. All these
actions are performed by hydraulic system under the computer control.
1.4 Mold Clamp Installation dimension ：

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1.5 Preparation before Purchase
1.5.1 How to order spare parts
When you intend to purchase spear parts, please provide the following information:
To sure the model, serial number and shipping date of your machine selected.
Code of the spear parts, location and ref. Number in the drawing of the Manual and
Quantities, they can be found in chapter 9.
You can buy the spear parts directly in the stores or nearby offices of HAITAI Machinery.
The model, serial number and production date of the machine can be found on the nameplate
of machine.
In case that component you need is not listed in the Manual or different from the manual,
please provide the manufacturer name and code number.
1.5.2 Selection & Specification
1.5.2.1 Calculate the injection capacity of the injection molding machine according to the
weight of product

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If the product is made from polystyrene, the injection capacity Wps shall be
Wps=(product weight + total weight of the runner system) / (0.75～0.90)
i.e. Wps=(1.3～1.1) ×(product weight + total weight of the runner system)
The larger coefficient is taken when high precision product quality is required.
If the product is made from other plastic (named X plastic), calculate the theoretic
injection capacity of the plastic, Wx, based on the aforesaid formula:
Wx=(1.3～1.1) ×(product weight + total weight of the runner system)
But you can’t decide the injection capacity of the injection-molding machine simple by
Wx, you have to exchange it into Wps. The formula is:
Wps=Wx ×1.05
Vx
In which, Vx represents the specific gravity of certain plastic.
For example: Suppose a plastic product is made from polyethylene (PE), its weight is
calculated to be 185g, and the weight of runner system is estimated to be 20g,
according to the aforesaid formula:
Wx = 1.2* (185+20) =246g
The specific gravity of PE Vx =0.92
So , Wps =246 ×1.05
0.92
The machine with 110z shot weight is recommended.
1.5.2.2 According to the perpendicular projection area of the product on the platen, calculate
the clamping force P:
Clamping force=clamping force constant ×projection area of the product
i.e. p = Wps
In which, P---- clamping force (t)
S---- perpendicular projection area on the platen (cm2)
Kp---clamping force constant (t/cm2)
Kp is listed in the following table 1

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1.5.2.3 The space between tie bars of the machine is dependent on and larger than the external size of
mold.
Table 1 clamping force constant Kp (for precise products)
Plastic
Description
PS
PE
PP
ABS
NYLON
POM
Fiberglass
Other
Engineering
Plastic
Kp (t/cm2)
0.32
0.32
0.32
0.30
0.64～0.8
0.64～0.8
0.64～0.8
0.64～0.8
1.5.2.4 The opening stroke of the injection molding is dependent on and larger than the height of the
product.
Fig.1-3
1.5.2.5 Other secondary considerations
The mold thickness of the injection-molding machine shall match you mold height.
Ejector stroke, ejection force.
Technical data.
The dimension, the material feeding become difficult, even worsts no feeding to effect an
operation.
Moving
platen
Mold
Mold
Fixed platen
Opening stroke

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Chapter 2 Machine Installation
2.1 Preparation before Installation
2.1.1 choice of hydraulic oil and lubricating oil (grease)
Hydraulic oil and lubricating oil are very important for the operation of injection molding
machine, so the user shall observe the requirements strictly for purchase and application of
them. Table 2-1 shows the recommended hydraulic oil, lubricating oil and grease.
The hydraulic oil and lubricating oil must be chosen carefully; otherwise, you cannot fully
utilize the excellent performance of the machine.
Not to make environmental pollution while using hydraulic oil and lubrication oil.
Table 2-1 recommended hydraulic oil and lubrications
BRAND
SHELL
MOBIL
ESSO
FEOSO
CHINA
(AREA)
Hydraulic
oil
TELLUS46
DTE25
TRERSS046
HYDROSO46
N46 Anti-wear
Hydraulic oil
Lubricating
oil
TONNA
T68
VACTRA
OIL
HEAVY
MEDIUM
MILLCORK150
Or TERESS068
HYDROSO100
Machine oil
N220 (for
southern area)
N100 (for
northern area)
Grease
Lithium base
Grease
2.1.2 electricity and cooling water
First, the user should get the required power supply and cooling water ready.
You may, according to the data of instruction, generally determine the power supply, source
and layout of the cooling water. As the machine may be different in some way from the oral
or written descriptions provided by us, the user shall make proper changes of the power
supply and water source while installing the machine.
If necessary, accessories are required for a suitable cable and pipe installation.

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2.2 Lifting machine
Check whether there is something damaged with the machine and whether it is
confirmation in good conditions before lifting.
If the machine gets damage during transportation, be sure to report in time and make a
record.
It shall be noted that during the storage and handling of the equipment, the allowable
ambient temperature to the equipment is between -25℃and 55℃;in case the temperature has
to be exceeding 70℃, the equipment shall be not exposed to such temperature for more than
24 hours.
The equipment is large and heavy. The following points shall be noted in lifting:
※For the safety and stableness in the process of lifting, please refer to Fig. 2-1.
※The crane must have sufficient lifting capacity;
※The pulling cable should be tied according to the specified position shown as Fig. 2-1
any other part of machine mustn’t be tied in order to protect the machine;
※The steel cable and hook must be strong enough and damage –free (see machine weight
in the table 2-1);
※The machine should be protected to prevent any scratched or other damages.
※Please make reference to Fig.2-1 when the equipment is handled with forklift. The
primary requirement is a forklift of sufficient capacity to ensure the balance when
handling, and no tilting shall occur to ensure the safety and stabilization when handled
up and downward.
※A wooden pallet recommended is placed under the equipment to facilitate the handling
with forklift.
※In case no such pallet is available, some soft material shall be padded under the
equipment to avoid scratching.
※It is shall take care during handling operation. The handling point shall be on the center
of gravity of the equipment.
※The lift personal should be qualified.
※All the exposure parts, such as leaders, tie-bars and surface of platens should be wiped
antirust before transporting.
Caution: Do not remove antirust oil with impregnant, use soft material such as paper
or clothes only.

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Fig.2-1
Table 2-1 Machine weight unit：ton
Model
HTW200
Weight (not including oil)
7
2.3 Installation and commissioning
2.3.1 Installation foundation
If the machine will be installed on a concrete base, make sure that it’s strong enough.
Leveling pad can be also be used for the purpose of leveling as well as a vibration absorbent.
lifting ring
fixed platen

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Fig.2-2 HTW200 foundation plan
Shockproof heel block or foundation bolt
Notice ：
Keep machine’s circumference clean.
Fig.2- 3 adjustable iron plate
Refer to the clause 2.3 to use foundation bolts to fix the machine on an intensified concrete
floor.
Leveling pad can also be used for the purpose of leveling as well as a vibration absorbent
see Fig.2-3.
If the machine will be installed on a concrete base, make sure that it’s strong enough.
Quantity of foundation bolt and shockproof heel block unit: pcs
Model
HTW200
Foundation bolt
6-M16
Adjustment block
6
2.3.2 Site
The place see Fig.2-4 where the machine is installed should be free of humidity and dust。
And have sufficient space for installation, commissioning, and maintenance etc. sufficient
space shall be left at least 1000mm.