Wittmann Battenfeld VM R B8 Series User manual
INSTRUCTION MANUAL
Read before using
the injection moulding machine
and keep nearby for reference.
VM R B8 PRODUCT LINE
VR2GBB8V00 0217
Wittmann Battenfeld GmbH
Wr.Neustädter Straße 81 • 2542 Kottingbrunn • Österreich
Tel. +43 (0) 2252 404-0 • Fax +43 (0) 2252 404-6102
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.
TECHNOLOGY working for you.
instruction manual
Production line
Machine model
Control system type
Machine number
Year of manufacture
Numbe rof instruction manual
Date of issue
VM
xxx/xxxx/xxxxx R XXXX
UNILOG B8
137xxx-100
2017
VR2GBB8V00_0217
16.02.2017
VR2GBI2B800A
0217TW Index - 1
1.................................................................................................................Preface
1.1.......................................................................................................................................................... Introduction
1.2..............................................................................................................................................Area of Applicability
1.3........................................................................................................................................Explanation of symbols
1.4..............................................................................................................................................................Copyright
1.5...............................................................................................................................................Transfer Certificate
1.6...................................................................................................................................... Certificate of Conformity
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...................................................................................................................................................... Miscellaneous
3.1.1......................................................................................................................................... Hydraulic equipment
3.1.2..........................................................................................................................................Electrical equipment
3.1.3.................................................................................................................................................... Water system
3.2............................................................................................................................Pump output VM 40 - VM 270
3.2.1.........................................................................................................................Pump output VM 60 - VM 200
3.3....................................................................................................................... UNIFEED material feeder (option)
3.4...............................................................................................................................................Injection unit VM R
.........................................................................................................................................................VM 40/ ... R752
.......................................................................................................................................................VM 60/ ... R1040
.......................................................................................................................................................VM 75/ ... R1040
..................................................................................................................................................... VM 110/ ... R1280
.....................................................................................................................................................VM 150/ ... R1280
.....................................................................................................................................................VM 150/ ... R1520
.....................................................................................................................................................VM 200/ ... R1520
.....................................................................................................................................................VM 200/ ... R1755
....................................................................................................................................................VM 270/ ... R1755
3.4.1............................................................................................................................................... Injection unit VM
........................................................................................................................................................................VM 60
........................................................................................................................................................................VM 80
......................................................................................................................................................................VM 100
......................................................................................................................................................................VM 150
......................................................................................................................................................................VM 200
VR2GBI2B800A
0217TW
Index - 2
3.5.............................................................................................................................................Clamping unit VM R
.........................................................................................................................................................VM 40/ ... R752
.......................................................................................................................................................VM 60/ ... R1040
.......................................................................................................................................................VM 75/ ... R1040
..................................................................................................................................................... VM 110/ ... R1280
.....................................................................................................................................................VM 150/ ... R1280
.....................................................................................................................................................VM 150/ ... R1520
.....................................................................................................................................................VM 200/ ... R1520
.....................................................................................................................................................VM 200/ ... R1755
.....................................................................................................................................................VM 270/ ... R1755
3.5.1..............................................................................................................................................Clamping unit VM
...................................................................................................................................................................VM 60/ ...
...................................................................................................................................................................VM 80/ ...
.................................................................................................................................................................VM 100/ ...
.................................................................................................................................................................VM 150/ ...
.................................................................................................................................................................VM 200/ ...
3.6....................................................................................................................................... Dimension of the mould
3.7.................................................................................................................................. Operation of the feed zone
3.8.................................................................................................................................................................. Layout
3.10...........................................................................................................................Weights of screws and barrels
3.11......................................................................................................................Conversion table for shot weights
3.12................................................................................................................................. Tightening torque for bolts
3.12.1.................................................................................................................................................General screw
3.12.2.....................................................................................................................................Stud bolts / setscrews
3.13.................................................................... Torque settings for the fastening screws of the screw barrel head
4......................................................................................... Transport - Installation
4.1............................................................................................................................................. General information
4.1.1..........................................................................................................................................Unpacking / storage
4.1.2..........................................................................................................................................................Unloading
4.1.3....................................................................................................................................Space requirement plan
4.1.4.......................................................................................................................................... Packing instructions
4.5 ................................................................................................................................... Transporting the machine
............................................................................................................................................................ Transport VM
.........................................................................................................................................................Transport VM-R
4.2.1................................................................................................................................................. Machine weight
4.2.2...................................................................................................................................Transport safety devices
4.3........................................................................................................................................... Erecting the machine
4.4............................................................................................................................ Removing preservative agents
4.5.......................................................................................................................................... Levelling the machine
4.10................................................................................................................................................Hydraulic system
4.10.1...............................................................................................................................................................Filling
4.10.2............................................................................................................ Commissioning of the hydraulic pump
4.10.3.......................................................................................................................................................... Bleeding
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
VR2GBI2B800A
0217TW Index - 3
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............................................................................................................................................................. Interfaces
5.5................................................................................................................................ Checking the safety devices
5.6....................................................................................................................................Test run and interlock test
6..........................................................................................Structure and function
6.1....................................................................................................................................................... Clamping unit
6.1.1..........................................................................................................................................Clamping unit VM R
6.1.2..............................................................................................................................................Clamping unit VM
6.1.3...................................................................................................................................Central lubrication pump
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
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 1330
6.2.5.2...............................................................................Retooling for a different screw diameter up to size 1330
6.2.5.3...............................................................................................................................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
6.3.1.......................................................................................................................................... General information
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
VR2GBI2B800A
0217TW
Index - 4
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................................................................................................................. Three phase asynchronous motor
6.6.1.2........................................................................................................................Speed-controlled servo motor
6.6.2...................................................................................................................................................Switch cabinet
6.7..............................................................................................................................................UNILOG B8 control
6.7.1.......................................................................................................................................... General information
6.7.2.................................................................................................................................................. Operator panel
6.7.3................................................................................................................................. Explanation of the picture
6.7.4................................................................................................................................................Saving / Printing
6.7.5..........................................................................................................................................Control components
7............................................................................................................. Operation
7.1...................................................................................................................................................... Miscellaneous
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
VR2GBI2B800A
0217TW Index - 5
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
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
VR2GBI2B800A
0217TW
Index - 6
EWAGB0AD
0516TW Chapter 1 - 1
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.
EWAGB0AD
0516TW
Chapter 1 - 2
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).
The parameters for the machine heating must be set according the specification of the supplier of
processing materials!
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.
EWAGB0AD
0516TW Chapter 1 - 3
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.
EWAGB0AD
0516TW
Chapter 1 - 4
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)
EWAGB0BD
0516TW Chapter 2 - 1
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.
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.
EWAGB0BD
0516TW
Chapter 2 - 2
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.
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.
EWAGB0BD
0516TW Chapter 2 - 3
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.
EWAGB0BD
0516TW
Chapter 2 - 4
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.
At least, facial protection and gloves should be worn during all work such as equipping, start-up,
trouble-shoooting, etc.
EWAGB0BD
0516TW Chapter 2 - 5
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).
EWAGB0BD
0516TW
Chapter 2 - 6
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).
This manual suits for next models
9
Table of contents
