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. [phone] • Fax [phone]
[email protected]
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

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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

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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

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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

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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

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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

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0217TW
Index - 6