EN-G 11 30 35 11-2017-08-24 2047 Tdo8

DUO 2460/500
Serial No.: 219571
Service Manual - Machine

ENGEL duo
! WARNING!
Improper use of the machine can lead to severe injury to persons and damage
to equipment!
You must read this instruction manual carefully and familiarize yourself with
the safety precautions before operating the system or carrying out any mainte-
nance.
You must ensure that the persons carrying out the activities on the machine
have read and understood the relevant sections and chapters of the instruc-
tion manual.
ENGEL AUSTRIA GmbH

A-4311 Schwertberg
Tel.: +43.50.620.0 | Fax: +43.50.620.3609
service@engel.at | http://www.engelglobal.com
Person responsible for documentation: Harald Pichler
Version: G/11/30/35/11
Printing date:24.8.2017
Language:Englisch
Translation of original instruction manual
The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed, trans-
mitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (§12 and §13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
© Copyright by ENGEL Austria Ges.m.b.H.
Table of contents
Table of contents
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Structure of the system documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Occupational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Personal protection gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Thermal hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Mechanical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Gases, vapors and dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.8 Electro-magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Machine labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8 Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9 Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10 Applicable European standards and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 Safety conformity pursuant to Machine Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11.1 Safety-compliant machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11.2 Not safety-compliant machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Safety distance to the fixed equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Removing the injection unit transport safety brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Remove the clamping unit transport safety brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Connecting the frames of the clamping unit and the injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 Coupling the injection unit on the stationary mold fixing platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Leveling the injection molding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11 Align mold fixing platens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
12 Fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13 Vent the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
14 Vent hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
15 Cleaning after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
16 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
16.1 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
16.2 Network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
16.3 Cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
16.4 e-flomo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
16.4.1 Cooling water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
16.4.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
16.5 Compressed air supply (maintenance unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
16.5.1 Compressed air monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
17 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
17.1 Commissioning the injection molding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
17.2 Serviceapplication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
17.2.1 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
17.2.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.2.2.1 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.2.2.2 Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
17.2.2.3 Software packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
17.2.2.4 Data administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
17.2.2.5 System information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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Table of contents
17.2.2.6 User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

17.2.2.7 Date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
17.2.2.8 Network configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
17.2.2.9 Network drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
17.2.2.10 Start-up mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
17.3 Venting a pressure pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
17.4 Temperature control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Setting up for injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1 Nozzle centricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.1 Correct crane lifting of molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.1.1 Attach both mold halves at the same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.1.2 Attach each mold half individually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.2 Correct centering of mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.2.1 Standard applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.2.2 Heavy molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.2.3 Special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2.4 Mold anti-twist safeguard (rotational centering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.3 Correct mounting the mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3.1 Mounting of both mold halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3.2 Mounting of individual mold halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.3.3 Factors affecting mold performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.4 Checking the coaxiality of the two mold halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.5 Influencing factors of the injection molding machine on mold closing behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.6 Blow out cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3 Setting up the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Remove barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5 Install barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6 Changing a nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7 Removal of barrel flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8 Barrel cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9 Nozzle stroke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9.1 Calibrating the nozzle stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1.1 Maintenance interval 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2 Check machine - Ever-Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3 Cleaning of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.1 Cleaning the control panel on the ENGEL control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.2 Clean air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.3 Clean cooling water filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.4 Valve cleaning crossbar cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4 MuCell maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.1 MuCell T series integrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.2 MuCell SII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5 Maintenance of the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.1 EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.2 Moving safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.3 Mounting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5.4 Maintenance safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.5 Safety limit switch for swiveling out injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.6 Fixed gate for delivery chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.7 Contact multiplication safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
6.1 Lubrication Clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1.1 Lubricate pivot mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1.2 Lubricate the high-speed clamping cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1.3 Lubricate guide carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
6.1.4 Lubricate guide carriage - safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.1.5 Lubricate tiebar pulling device (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6.2 Lubrication Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.2.1 Lubricate guide carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.2.2 Lubricating the swiveling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.2.3 Replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.2.4 Change oil of the plasticizing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.2.5 Change oil of screw bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.2.6 Oil change at the screw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4 Service Manual - Machine | Version G/11/30/35/11

Table of contents
6.2.7 Gear assembly oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

6.3 Overview lubricants and hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6.3.1 Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6.3.2 Hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6.3.3 Food-safe lubricants and hydraulic oils (NSF-H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
7 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
7.1 Change hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
7.1.1 Fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7.1.2 Vent the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
7.1.3 Vent hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.1.4 Change the hydraulic oil from zinc-containing to zinc-free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
7.2.1 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
7.2.2 Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
7.2.3 Hose safety catch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7.2.4 Manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.3 Oil temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
7.3.1 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7.4 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
7.5 Auxiliary flow filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.6 Bladder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
7.6.1 Check and fill the bladder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
7.6.2 Check and fill the diaphragm accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
8 Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8.1 Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8.2 Hoses for the pneumatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
9 Service Request 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1 Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2 Removal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1 ENGEL manuals CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2 List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.1 Design drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.2 Hydraulics schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.3 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.4 Ordering spare parts without a material number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3 e-flomo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.1 Ball valves in the central flow and return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.2 Sensors, valves and electronics box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Plans and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2 Foundation plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3 Transport documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4 Mold mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
6 Pressure accumulator test certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Special programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
5
Table of contents

Structure of the system documentation
Instruction Manual - Machine
Operator Manual - Machine (Operation)
Service manual - Machine (Commissioning, Maintenance)
ENGEL Manual CD contains the following documents in PDF format:

Operator, Service and Technical Manual (Troubleshooting), schematics,
data sheet, safety data sheets, spare parts list and optional peripheral
unit documentation
MuCell Manual
Instruction Manual - Robot
Operator Manual - Robot (Operation)
Service manual - Robot (Commissioning, Maintenance)
ENGEL Manual CD contains the following documents in PDF format:

Operator and Technical Manual (Troubleshooting), spare parts cata-
log, schematics, data sheet and optional peripheral unit documenta-
tion.
An integrated help system is available in the machine control for easier support.
This covers the Operator, Service and Technical manuals.
A plan of the electric system is located in the control cabinet.
7

General
General
You have decided on an ENGEL product which is produced and supplied under strictest qua-
lity controls.
This instruction manual is an important part of the injection molding machine and intended for
any staff who work with or on the machine. Keep the instruction manual throughout the service
life of the machine, and pass it on to any subsequent owners or users. It is important to integ-
rate any amendments you receive with the instruction manual.
This manual's primary aim is to teach you how to maintain the injection molding machine.
The manual is also designed help eliminate production failures as rapidly as possible.
Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.
The index contains a list of alarms.
NOTICE!
Danger of damage to equipment!
The settings in the figures are purely incidental and should not be used as a
guide for a machine setting.
The process information refers to thermoplastic processing.
Information
All images are symbolic images and may deviate from the actually delivered plant.
1 Proper Use
ENGEL products are built to the current state-of-the-art, and comply with accepted safety stan-
dards.
Note that ENGEL injection molding machines must be used for manufacturing of injection
molded parts made of thermoplastics, thermosets and elastomers only, in accordance with the
instruction manual.
To this end, make sure you follow the processing instructions given by the material manufac-
turer!
(Improper processing could lead to injury or damage to equipment!)
The injection molding machines are constructed for automatic material feed.
Automatic material feed must be present at the site prior to start of production.
In case of manual material feed, a standardized mounting aid must be used.
The mounting aid can be supplied by ENGEL if required.
A mounting aid of this kind must be present at the site prior to start of production.
See mounting aid in the ’Operator Manual - Machine’.
For damage from improper or not as agreed use, non-observation of the specifications in the
instruction manual as well as faulty operation ENGEL GmbH is not liable.
Modifying the machine invalidates its EC conformity; you are not permitted to put the machine
into operation in this case!
9
General
2 Text formatting
The following text formatting, signal words and symbols are used to emphasize particularly
important information:
! DANGER!
Hint to immediately impending dangers, which can entail death or serious
physical injuries!
! WARNING!
Hint to possible dangers, which can entail death or serious physical injuries!
! CAUTION!
Information on potential hazards that may result in minor personal injury!
NOTICE!
Warning of possible dangers which can cause damage to the machine!
Information
Application tips and useful information.
Example:
Practical examples for the better understanding.
Numbered sequence
1. Fixes procedure way after the numbers.
2. The operator must adhere absolute to the fixed operational sequence.
 Information on the result of a step.

General
3 Safety hints
! WARNING!
Injection molding machines create high pressures, forces and temperatures
that can cause a risk of accidents to persons.
To protect persons against danger of accidents, ENGEL injection molding
machines are fitted with safety equipment.
Additionally observe the following points for your own safety.
3.1 Occupational safety

Improper use of the machine can lead to severe injury to persons and damage to equipment!
You must read this instruction manual carefully and familiarize yourself with the safety precau-
tions before operating the system or carrying out any maintenance.
You must ensure that the persons carrying out the activities on the machine have read and
understood the relevant sections and chapters of the instruction manual.
3.2 Qualification
Qualification of the staff depends on the activities to be carried out. For this purpose, ENGEL
defines different user roles and user levels. The below mentioned table mentions activities that
may be carried out by the relevant staff.
Precise description of the user roles and levels can be found in the ’operation’chapter.
 Trained operations staff

A person who has received training by a specialist professional, particularly on the tasks
assigned to him or her and on the dangers that can occur as a result of improper behav-
ior.
ENGEL user role: production staff
 Qualified operations staff

Staff who, based on their training, experience and instructions received as well as their
knowledge of relevant standards, can assess tasks assigned to them and can identify
and avoid potential hazards.
ENGEL user role: installer, quality manager
 Qualified specialist staff

Staff who, in addition of being qualified operations staff, have completed sound techni-
cal training.
ENGEL user role: process technician, maintenance engineer, all rounder
11
General
Activity Trained opera- Qualified opera- Qualified spe-

tions staff tions staff cialist staff
User level 3 User level 7-9 User level 11
Transportation
Installation
Commissioning
Conversion
Switch on and shut down

plant
Simple tasks during nor-

mal operation (refill insert
parts, clear finished parts
from conveyor-belt, etc.)
Simple adjustments and

simple troubleshooting
tasks
Mechanical/electrical trou-
bleshooting
Maintenance
Disassembly
Disposal
= authorized task
Only appropriately trained staff may perform tasks assigned to them on ENGEL plants.
Appropriate training is available on www.engelglobal.com/training and at the ENGEL

training centers.
3.3 Personal protection gear

Always wear approved protective clothing when working on the system (e.g. safety shoes,
safety gloves, face protection). Any other personal protection gear depends on the material
you are processing. For more details, consult your material supplier.
Observe local safety regulations for operating injection molding machines!

General
3.4 Place of work

To ensure risk-free operation, observe the following basic rules in the work environment:
 Always keep the whole plant clean. This improves its functionality and enhances opera-
tor safety!
 The floor around the plant as well as the specified access points and working places are
to be kept free of oil and pellets.
 Only use marked locations as access points or workplaces.
 Protect hoses against harmful influences such as acids and mechanical damage!
 If you notice leakages, damage, or breaks in media lines, switch off the machine imme-
diately!
 Never use plant surfaces as work surfaces. Do not use the plant as a mounting aid.
 Comply with and never remove warning signs, notices or labels from machines!
 Familiarize with safety devices. Refer to ’Operator Manual - Machine ’.
 Observe the safety instructions in the manual!
 No access for unauthorized persons.
 Use a suitable mounting aid for work above 1.0 m (39.4 in).
If you need to use a mounting aid, use equipment that complies with local safety regu-
lations and prevents from falling, tripping or slipping.
 Unauthorized, non-permanent mounting aids can allow staff to reach into dangerous
areas of the machine.
Before you use non-permanent mounting aids, always switch off the injection molding
machine.
 Never lean ladders against the machine!
3.5 Thermal hazards

Danger of burns in the vicinity of hot components such as the barrel and injection mold!
Insufficient pre-drying or decomposition of certain plastics can cause the material to exit the
nozzle or infeed opening in an uncontrolled way.
When working in the injection mold area, make sure the nozzle is retracted! Make sure the bar-
rel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufacturer!
3.6 Mechanical hazards

 Danger of crushing due to moving components!
During operations never reach into, or enter, component work areas, except at positions
designed for this purpose.
Never manipulate, disable, or remove safety equipment.
Do not use any molds that protrude over the mold area of the machine.
Do not work or stand below moving components, even if the plant is switched off.
13
General
 Danger due to high pressure injection during work on the injection mold and nozzle
area!
When working in the injection mold and nozzle area, make sure that the process mate-
rial is pressureless.
In case of injection steps where clamp force is not fully built up, install additional, fixed,
separating safeguards in the injection molding machine mold area, or attach directly to
the mold!
When connecting and disconnecting media lines in case of retooling work, make sure
that the system is depressurized and switch off the motors.
3.7 Gases, vapors and dusts

Observe processing and safety instructions by the material manufacturer. When processing
materials that can cause a health risk, always use extraction equipment.
The owner is responsible for deploying the extraction equipment (e.g. above the injection
mold, nozzle area, material feed opening).
When using nitrogen in processes, always check the oxygen content first before all work in the
pit.
3.8 Electro-magnetism
Pacemakers, hearing aids and other medical devices can be damaged or affected by the use
of the magnetic holding system.
Do not use any objects that contain iron in the vicinity of the magnetic holding system surfaces
when it is magnetized. The great forces can cause crushing points.
Do not magnetize the magnetic holding system when the mold is not in contact with the sur-
face of the magnetic holding system.
Read and comply with the operating manual of the magnetic holding system!
3.9 Setup work

When operating the machine, use settings that precisely match the requirements for safe oper-
ations of the machine, robot, molds, material and peripheral units.
ENGEL is not liable for operator errors.
3.10 Maintenance
Maintenance and repairs of the plant may only be performed by authorized and qualified staff
observing occupational safety rules.
You must have comprehensive knowledge of safety precautions and controls.
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.

General
4 Pictographs
Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Symbol Description and examples of labels
Admittance for authorized persons only!

Standard labels on protection doors for safety guarding
Keep off the area!

Standard labels in the area of the injection unit and robot control cabinet
No admittance for persons with cardiac pacemaker!

Labels for magnetic holding plates in the clamping unit area
Working or standing below moving components and suspended loads is prohib-

ited!
Labels for machines with robots on protection doors, clamping unit and safety
guarding
No fork lift trucks!

Use of fork lifts or manual lifts for lifting the plant at this position is prohibited.
Do not use any credit cards, watches or small metal parts in the proximity!
Labels for magnetic holding plates in the clamping unit area
Filling with zinc-based hydraulic oil not permitted!

Standard mounting adjacent to hydraulic oil reservoir. Remove the pictogram
when changing to zinc-based hydraulic oil!
15
General
Read documentation!
On the control panel of the machine control
Use protection equipment!

In the barrel area
Use face protection!

In the barrel and injection mold area
Use safety belt!

On the mounting aid
Use lifting point for transport!

At lifting points
Warning against hot surface!

In the barrel area
Warning against mains voltage!

On control cabinets and distribution boxes
Warning against hand injuries!
Warning against floating loads!
Warning against pinching or squeezing!

In the clamping unit area
Warning against pressurized molten material!

In the barrel area
Warning against strong magnetic field!

General
Symbol Description
GUIDELINES FOR WORKING ON INJECTION MOLDING MACHINES:

Labels for the machine control
1. Always observe the local safety regulations for the operating safty of injection
moulding machines and robot systems (handling systems, mould change).
Read the instruction manual.
2. Keep safety equipment in good working condition. Never remove, deactivate
or disable safety equipment.
3. Do not remove any danger or information signs and markings from the
machine or from the additional equipment.
4. Control all the safety equipment on the machine and on the additional equip-
ment for correct function and check it at regular intervals.
5. Control all high-pressure pipelines at regular intervals for their worksafe
state.
6. Pay attention to that no hard objects get into the vent as well as into the feed
opening.
7. Entering the area of the injection unit is not allowed during the machine oper-
ation.
8. If a mounting aid is required for filling the processing material container, use
such which corresponds to the local safety regulations.
9. Do not enter the ejection area and/or do not reach into it during operation.
10. Caution in the area of the heated-up material cylinder ready for operation
(danger of combustion).
11. Always observe the processing guidelines and safety hints indicated by the
material manufacturer.
12. Use extractor fans when working with a vented cylinder and when process-
ing toxic types of material; wear the prescribed protective clothing.
13. Only use shut-off nozzles allowed by the legislator.
14. Never switch the main switch under load (e. g. when heatings are switched
on).
15. Switch off the motors for all maintenance and repair work in the machine's
work areas with moving parts. Make sure that the complete hydraulics system
is depressurized. Exercise special care if you use pressure accumulators.
16. Set the machine currentless by all means in case of repairs and modifica-
tion work. Switch off main switch and secure it and control for voltage freedom.
17. Make sure that the material in the material cylinder is not under pressure
and/or is not cooled down before you dismount the nozzle and/or the material
cylinder flange.
18. Mount and check the whole safety equipment after machine repairs.
19. No admittance to the machine for unauthorized persons.
Entering the injection unit during operation is not permitted, otherwise attach
suitable cover which prevents people from reaching into the hazard area.
Labels for the injection unit
17
General
5 Machine labeling
The machine is labeled with symbols to the extent possible. Where this is not possible, bilin-
gual labels are used. There follows an explanation of the symbols used.
Component
Depiction of the machine components.
general Machine Non-opera-

front side tor side
Stationary platen
Moving mold fixing

platen
Mold swivelling
device
Sliding table
Vertical clamping
unit side
Injection unit
Ejector coupling
Core
Air valve
Nozzle
Shut-off nozzle
Shut-off nozzle pneu-

matic
Static mixer
Lifting table
Step safety
Feed throat cooling
Oil cooler
Medium
Depiction of the relevant medium.

General
Compressed air
Water for tempera-

ture control
Cooling water
Oil
Media connections
Depiction as circuit; the arrow shows the flow direction.
Advance or
Return or
Temperature control medium manifold

Depiction of temperature control medium's manifold.
Cooling water mani-

fold
e-flomo
Temperature control
device
Example:
Label for a rotating union
Core to rotary table, connection A move in core, connection B

move out core
Core to station 1, connections 3 and 4
Core to station 2, connections 1 and 2
Water, left advance, right return
1st circuit to station 1, connections 5 and 6
2nd circuit to station 1, connections 7 and 8
Station 2 with connections 9 and 10
Compressed air to connection 11
Circuit to rotary table station

Rotary table station
19
General
6 Type plate
The type plate is attached to the injection molding machine for the purpose of unambiguous
identification.
Example: Injection molding machine
Type plate
Example: information on the type plate
1 2 3
5 6
[1] Company name

[2] Machine Number
[3] Year of construction
[4] Type designation
[5] Mass
[6] Machine type

General
7 Additional equipment
Additional equipment, e. g. robots, conveyor belts etc. may only be mounted with approval by
ENGEL. ENGEL is only responsible for the cooperation of the machine with additional equip-
ment if the interfaces have been designed by ENGEL.
! DANGER!
Danger of fatal injury due to high voltage!
There is a risk of injury or even death due to components that have become
live.
Additional equipment (e. g. conveyor, drier etc.) must be connected with the
machine potential electrically well conducting (potential equalization as per EN
60204-1).
! WARNING!
Danger due to missing safety gates!
Hazardous movements at the injection molding machine are accessible if the
safety gates are absent.
If safety gates are disassembled for machine operation with additional equip-
ment, safety measures must be taken by the operator, which do not reduce the
safety level!
Restore the original status of the safety gates for machine operation without
additional equipment.
Observe the following conditions when mounting additional equipment:

 Mount additional equipment in such way that hazardous machine areas can be seen
and so that access to the workplaces specified in the instruction manual is possible.
 If additional equipment is attached to the machine without ground support, it will be nec-
essary to reevaluate the risk of tipping.
 A risk assessment by the robot manufacturer is necessary for connection and safe use
of the interface for robots/automation according to Euromap 67 or Euromap 12.
 Use sockets on the injection molding machine only for the specified additional or periph-
eral equipment.
21
General
8 Behavior in case of fire
1. Keep calm
2. Alert the fire department
3. Switch off the machine at the main switch
4. Alert all persons in the danger zone
5. If possible, close all fire doors
6. Switch of any venting and/or air conditioning units
7. As soon as possible, contain the fire with an approved fire extinguisher
8. Provide assistance and direction to anyone actively involved in fighting the fire
Use an abc class fire extinguisher

 This is most suitable due to its versatility compared with other extinguishing agents.
 Be familiar with the instruction label attached to the fire extinguisher.
 Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.
! DANGER!
The use of incorrect extinguishing agents may result in fatal injury!
Not every fire extinguisher can be used for all fires. Electric shocks or grease
explosions may be the result.
Observe instructions on fire extinguisher when extinguishing a fire (fire
classes, distance from source of the fire, etc.)
Information
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:
 at your local ENGEL dealer/subsidiary, or

 contact the nearest ENGEL works

General
9 Rescue actions
The operator of the injection molding machine shall provide adequate assistance in accor-
dance with local regulations. After an accident, a suitably qualified helper shall extract injured
persons from the danger zone and administer first aid.
10 Applicable European standards and regulations
2006/42/EG Machinery Directive
2014/30/EU EMV-guidelines
EN ISO 12100 Safety of machinery - General principles for design - Risk assess-
ment and risk reduction
EN ISO 13857 Safety of machinery - Safety distances to prevent upper and lower
limbs from reaching the hazard zones
EN 201 Plastic and rubber machines - Injection molding machines - Safety

requirements
EN ISO 13850 Safety of machinery - Emergency stop - General principles for design
EN ISO 14120 Machine Safety - separating safety device
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: Gen-

eral requirements
EN ISO 10218-1 Industrial robots - Safety requirements - Part 1: Robots
EN ISO 13849-1 Safety of machinery - Safety-related parts of control units- Part 1:

General principles for design
23
General
11 Safety conformity pursuant to Machine Directive

Machines are delivered safety-compliant with CE mark or incomplete for incorporation in a
total system.
 In the case of a safety-compliant machine, the ’Service Manual Machine’ Chapter
’Drawings and Certificates’ contains a declaration of conformity.
 In the case of a non-safety-compliant machine, the ’Service Manual Machine’ Chapter
’Drawings and Certificates’ contains a declaration of incorporation.
11.1 Safety-compliant machine

The EC declaration of conformity is located in the ’Service Manual Machine’ in Chapter ’Dra-
wings and protocols’.
The machine is safe to operate and ready for operation after setup and start up by an autho-
rized person.
! WARNING!
There is a risk of fatal injury in the case of incorrect assembly!
The injection molding machine may only be assembled by authorized persons.
Observe the safety instructions in the manual.
All supplied safety gates must be mounted prior to starting up.
The following conditions must be fulfilled to enable the injection molding machine to be prop-
erly assembled without compromising the safety and health of persons:
 Suitable means of transportation and sturdy mounting aids.
 Load-bearing capacity of installation site (see data in foundation plan).
 In order to work on the machine, you must ensure that access is possible from all sides.
Maintain minimum distances from fixed equipment (see foundation plan and transport
sketch).
 Transport, install and connect the machine as per the Chapter ’Installation and commis-
sioning’ .

General
11.2 Not safety-compliant machine

The EC declaration of conformity is located in the ’Service Manual Machine’ in Chapter ’Dra-
wings and protocols’.
! WARNING!
Danger of fatal injury due to missing protective equipment!
Starting up the incomplete injection molding machine is prohibited.
Install the injection molding machine in the total system according to the
assembly instructions and safeguard the danger zone.
You are not permitted to operate the system until an authorized expert has
type-approved the machine and confirmed that safe operations are given, and
until a declaration of conformity has been presented, and a CE sign has been
attached to the system.
Example of a system
3 4
[1] Injection molding machine (e.g. by Engel)

[2] Conveyor belt with protective tunnel (e.g. by third party supplier)
[3] Safety guarding with safety gate (e.g. by customer)
[4] Robot (e.g. by Engel or third party supplier)
25
General
Assembly instructions
! WARNING!
There is a risk of fatal injury in the case of incorrect assembly!
The machine may only be assembled by authorized persons.
Heed the safety notes in the instruction manual.
All supplied safety gates must be mounted prior to starting up.
The following conditions must be fulfilled to enable the injection molding machine to be prop-
erly assembled with other components to a complete plant without compromising the safety
and health of persons:
 Suitable means of transportation and sturdy mounting aids.
 Load-bearing capacity of installation site (see data in foundation plan).
 In order to work on the machine, you must ensure that access is possible from all sides.
Maintain minimum distances from fixed equipment (see foundation plan and transport
sketch).
 Ambient conditions see ’Service Manual Machine’.
 The machine is to be set up in the following sequence:
1. Injection molding machine
2. Robot
3. Peripheral unit and safety guarding
For transport, setup and connection see ’Service Manual Machine’, ’Service Manual
Robot’ and peripheral unit.
Overview diagram and circuit diagrams, see control cabinets.
 All conductive components of the machine which may be under voltage in the case of
malfunction must be connected to the protective earth conductor.
 You are not permitted to operate the system until an authorized expert has type-
approved the machine and confirmed that safe operations are given, and until a decla-
ration of conformity has been presented, and a CE sign has been attached to the sys-
tem.

Installation and commissioning
Check the delivery immediately on arrival:

 Scope of delivery (refer to delivery note)
 Transport damage
 Visible defects
Have forwarding agent confirm all visible defects, and inform manufacturer in writing immedi-
ately.
1 Ambient conditions
The following ambient conditions are required on site to ensure trouble-free operation.
The machine is designed for operations in a closed room.
Note the following values in case of long-term storage and for operations.
Ambient air temperature

Minimum: +10 °C (50 °F)
Maximum: +40 °C (104 °F)
Atmospheric humidity (non-condensing!)

Minimum: 20 %
Maximum: 80 %
Corrosion stress
Corrosion category C3 with durability of 2 to 5 years according to DIN EN ISO 12944.
Urban and industrial atmosphere with moderate SO2 pollution and temperate climate.
For corrosion stress above corrosion category C3, there is an option to supply uncoated parts
of new machines as corrosion-resistant version.
Altitude
Maximum installation height: 2000 m (6560 ft) above sea level.
At installation heights in excess of 1000 m (3280 ft) above sea level, there may be a reduction
of drive power.
Electromagnetic compatibility
Must comply with EC EMC directive (2014/30/EC)!
Must comply with the North American Standard (NFPA79)!
27
2 Foundations
Consult a construction expert (expert builder or structural engineer) to make sure that the
foundations fulfill the following requirements:
 Load-bearing capacity of the existing shop floor sufficient?
 Establishment of a foundation required?
Information
Observe details in foundation plan!
 Space requirements: In order to work on the machine, you must ensure that access is
possible from all sides!
 Machine weight
 Machine pedestals
 Positions
 Maximum height adjustment
 External diameter

3 Transportation
Orderly transportation is the basis for the safety of all stakeholders and for trouble-free com-
missioning of the plant. For this reason, make sure that you observe the following instructions.
! DANGER!
Danger of fatal injury from floating loads!
Floating load hazard!
Transportation must be performed by skilled staff familiar with transportation
of machines.
 The transport sketch is in the ’chapter Plans and Protocols - Transport documents ’.
 Use appropriate lifting gear with sufficient load-bearing capacity. For weight refer to the
type plate on the machine or to the Plans and Protocols chapter (technical data, foun-
dation plan).
 Only use the marked lifting points for transportation; do not use bent or damaged lifting
gear. Check the routing of the cables from the lifting eyes to the lifting gear

At lifting points

 Modifications of the load suspension points are not permissible.

 Before the transport, please remove all moving safety gates using suitable slings
against any uncontrolled movements.
 The injection molding machine must be lifted and transported in horizontal position
(lengthwise and crosswise).
 For safe lifting of the injection molding machine, use lifting gear with 4 strands.
 Maximum spread of cables on the crane hooks 60°.
 Before lifting the machine, remove any obstructing components and use lifting gear with
edge protection if contact with the edges of neighboring components is possible.
 The clamping unit and injection unit must be secured against possible axial movement
by using the transport safety brackets provided. The rod bearings must be fully
extended. The clamping unit must be extended to the maximum mold height.
 Transportation of an injection molding machine by heavy goods vehicle is only permis-
sible if an anti-slip mat ( thickness 8 mm) is used.
 The position of the machine's center of gravity in the transport sketch may differ due to
customer options.
 The minimum capacity per lashing point on the heavy goods vehicle must be 2 t.
 Please refer to the transport sketch for machine-specific transport details, which take
priority over the standard details.
29
4 Installation
Machine shoes are used to level the injection molding machine.
These absorb horizontal and vertical forces and let the injection molding machine run quietly
and smoothly.
! DANGER!
Danger of fatal injury from falling loads!
This can result in serious personal injury up to death!
No standing under suspended loads. Transportation can only be performed by
trained staff familiar with transportation of machines.
Information
In the case of machines whose height can be adjusted, check if the adjustment spindles can
be fed through the holes drilled in the frame of the machine from the top.
1. Position the supplied machine pedestals and machine wedge shoes according to the
foundation plan.
Example Foundation plan
Machine wedge pedestal Machine shoe - for DUO 350 to 700

also at the clamping unit
2. Place the injection molding machine on the positioned machine pedestals.
Machine frame
Machine wedge pedestal Machine mount

3. Screw the lock nuts with shims onto the adjustment spindles.
Counter nut
Washer
Adjusting spindle
4. Grease the adjusting spindles using the supplied grease.
Grease
Adjusting spindle
5. Route the adjustment spindles through the machine frame bores.
Adjusting spindle
Machine frame
6. Adjust the machine frame upwards by turning the adjusting spindles clockwise.
[See Leveling the injection molding machine on page 43.]
For the maximum adjustment range of the machine pedestals, see the following table.
Machine frame
Adjusting spindle Adjusting spindle
31
7. After leveling the injection molding machine, tighten the counter nuts.
Counter nut
Machine frame
NOTICE!
When the adjustment range is exceeded, the stability of the injection molding
machine is no longer given.
Do not exceed the maximum adjustment range of the machine pedestals.
Designation Adjustment stroke
Machine pedestal SUNNEX MHD190-XL E13 24 mm
Machine pedestal SUNNEX MHD190 E18S 24 mm
Machine pedestal SUNNEX OSM4 15 mm
Machine pedestal SUNNEX OSM2 13 mm
Machine wedge shoe BWZ FK10/H 22 mm

5 Safety distance to the fixed equipment

When setting up machines with no injection gate, note the space requirement specifications
based on the foundation plan.
! WARNING!
Risk that bodies or body parts may become crushed!
Bodies or body parts may be crushed by moving components that extend
beyond the machine frame.
Keep a minimum distance of 500 |mm (20 in) between the rear position of the
moving injection unit and any fixed equipment.
This distance must be ensured at the maximum nozzle and plasticizing stroke.
min. 500 mm
(min. 20 in)
33
6 Removing the injection unit transport safety brackets

The transport safety brackets painted in red prevent the injection unit from unintended move-
ments during transport.
NOTICE!
If the injection unit is operated with the transport brackets in place, it will be
damaged.
Remove the transport safety brackets prior to commissioning the injection
molding machine.
Information
After removal keep the transport safety brackets for future transports.
Removal of the H-injection unit's transport clamps

There are 4 transport clamps at the H-injection unit; they must all be removed.
Example: transport clamps
Transport clamp
1. Remove counter nut and Allen screw.
Allen screw
Counter nut

2. Remove Allen screw and transport clamp.
Allen screw
Transport clamp
3. Remove sleeves and secure the guide rails using the provided shorter Allen screws.
Sleeve
35
4. Cover the Allen screws with the provided caps.
Caps
5. Loosen the clamping lever on the injection unit.
Clamping lever
 The H-injection unit's transport clamp has successfully been removed.

Removal of the transport safety brackets at the pull rods

There is a pull rods' transport safety bracket located at the H-injection unit; it must be removed.
Example: pull rod transport safety bracket
Transport safety
1. Dismount hexagon socket screws.

2. Remove the pull rods' transport safety bracket.
Transport safety
Allen screw
 The pull rods' transport safety bracket has successfully been removed.
37
7 Remove the clamping unit transport safety brackets

This dismounting procedure is not valid for clamping units that are transported in assembly
groups (clamping unit, stationary mold fixing platen, moving mold fixing platen, etc.)!
Spacers are mounted between the movable/stationary mold fixing platen and the transport
safety brackets on the locking nuts; these serve to provide stable transport.
Distance piece
Locking nuts
Distance piece
Procedure for dismantling transport safety brackets:

1. Remove the transport safety brackets from the four locking nuts.
Transport safety

2. Remove the screws from the spacer only on the movable mold fixing platen. The spacer
can be removed using suitable lifting gear only after commissioning.
Moving mold fixing platen
Distance piece
Screws
Information
If the injection molding machine is transported again, the transport safety brackets must be
reattached.
39
8 Connecting the frames of the clamping unit and the injec-

tion unit
1. In order to connect the frames of the clamping unit and the injection unit, bring the injec-
tion unit to the correct position.
2. Use the centering pin to align the injection unit.
3. Bring the threaded spindle of the clamping unit frame together with the consoles of the
injection unit frame.
Injection frame
Console
Threaded spindle
Threaded spin-
dle
Centring bolt Injection frame

Closing frame
4. Screw the injection unit frame to the threaded spindles and place them on the machine
pedestals. Then loosen the threaded spindles somewhat.

5. For basic adjustment, use a ruler on both sides to align the injection unit frame to the
same height.
Milled areas
Ruler
6. For basic adjustment, level the injection unit frame horizontally in the longitudinal direc-
tion. Carry out measurements on the guide rails using the precision water level.
7. Connect the hydraulic hoses and electrical connections of the injection unit to the
clamping unit.
41
9 Coupling the injection unit on the stationary mold fixing

platen
Procedure
Connect the nozzle contact cylinder of the injection unit to the connection pieces using the bolt
on the stationary mold fixing platen.
Bolt
Coupling
Nozzle carriage cylin-

der

10 Leveling the injection molding machine

The injection molding machine must be set up to be completely level. For maximum height
adjustment of machine pedestal, see foundation plans.
Leveling - check current machine level:
2
1
[1] Clamping unit measuring range

[2] Injection unit measuring range
[3] Machine pedestal (for position of all machine pedestals see foundation plans)
Measuring equipment: precision spirit level and level bar
Precision water level level bar
Procedure:
1. Loosen the Allen screws between injection unit frame and clamping unit frame.
43
2. Use a precision water level to check the clamping unit in longitudinal direction.
Tolerance 0.2 mm/m (0.0024 in/ft)
Precision water level
3. Use the leveling screws on the machine pedestals to longitudinally level the clamping
unit.
4. For the transverse measurement, mount the cylinder pins (which are in the accessories
box) on the stationary and moving mold fixing platen.
2 Cylinder pins per mold fixing platen
5. Install a level bar and precision spirit level for latitudinal measurement. Tolerance
0.2 mm/m (0.0024 in/ft)
level bar
2 Cylinder pins per mold fixing platen
6. Use the leveling screws on the machine pedestals to level the clamping unit in the trans-
verse direction.
7. Use the adjusting spindles on the machine pedestals to level the injection unit in the lon-
gitudinal and transverse directions. Measuring range longitudinally and 90° transversely
over the injection unit guide rails.

8. Tighten the counter nuts on the machine pedestals.

9. Tighten the Allen screws between injection unit frame and clamping unit frame.
Information
Level after commissioning; check again after a production time of approx. 4 weeks and adjust
if needed.
Repeat leveling if the machine leaves the installation position during production.
Check whether the machine is level once a year!
If machine pedestals show signs of wear or defects, replacement of all pedestals on the clamp-
ing or injection unit is recommended (to avoid the need to repeat leveling at frequent intervals).
45

11 Align mold fixing platens

After levelling the injection molding machine or at maintenance interval 4, the alignment of the
mold fixing platens must be checked.
Check alignment:
1. Mount supplied test mandrels on the stationary and moving mold fixing platen.
2. Check side deviation from stationary to moving mold fixing platen with a straight edge.
The deviation may not exceed maximum 0.2 mm (0.0024 in).
 Example: Test mandrel with the hexagon socket screws mounted in the centering
ring of the mold fixing platen.
Knife-edge straight-edge
Test mandrel
 Example: Test mandrel mounted in own bore.
Knife-edge straight-edge
Test mandrel
47
3. Check inclination of stationary and moving mold fixing platen with frame spirit level.
 The mold fixing platens must be inclined outwards at the upper tie-bars. The inclina-
tion must be between 0.1 and 0.2 mm/m (0.0024 in/ft).
Frame water level
4. Check plate parallelism at the 4 measuring points.
Upper measuring points
Inside micrometer
Lower measuring points
Clamping unit Tolerance
DUO 350 to 600 0,3 mm (0,0118 in)
DUO 650 to 1700 0,4 mm (0,0157 in)
DUO 2000 to 5500 0,6 mm (0,0236 in)
5. Align the stationary and the moving mold fixing platen if larger deviations are present.
 DUO 350 to 800 platen alignment adjustable via machine shoes. [See Leveling the
injection molding machine on page 43.]
 From DUO 800 [See Align mold fixing platens on page 47.]

12 Fill hydraulic oil

The machine is supplied as standard with an empty oil tank and may only be put into operation
after it has been topped up with hydraulic oil.
NOTICE!
Danger of damage to hydraulic equipment!
Mixing of zinc-based and zinc-free hydraulic oil will cause significant equip-
ment damage to hydraulic oil components (e. g. blocking of filter elements).
Do not mix zinc-based and zinc-free hydraulic oil. When topping up, always
use the same hydraulic oil as used for commissioning at the factory!
Overview of the hydraulic components
4
5
[1] Hydraulic oil reservoir with filling hole

[2] Low-pressure filter with soiling indicator (red button)
[3] Pump for oil filtration
[4] Oil cooler
[5] Sight glass
49
Overview of the hydraulic oils

Zinc-based hydraulic oil is used for initial commissioning at the factory. Therefore, zinc-based
hydraulic oil must be used for filling. When changing to zinc-free hydraulic oil note the instruc-
tions in the following chapter. [See Change the hydraulic oil from zinc-containing to zinc-free
on page 222.]
Hydraulic oils zinc-based
norm DIN 51524-2

ISO VG46
GEYSER ST 46
GEYSER S 46
HYD HLP 46
HYD HLP-SHS 46
Oils and lubricants by Lukoil and OMV are identical

products.
VITAM GX 46
RENOLIN B15
RENOLIN MR 46 MC
RENOLIN XTREM TEMP 46 PLUS
OSO 46
ENERGOL HLP HM 46
HYSPIN AWS 46
NUTO H 46

Hydraulic oils zinc-based
DTE 25
TELLUS S2 MX 46
TELLUS S2 M 46
SUNVIS 846 WR
RANDO
OIL HD C 46
AZOLLA ZS46
Information
The oil fill volume is specified on the oil nameplate on the machine or on the foundation plan.
Replace all of the hydraulic oil in case you have to change the hydraulic oil brand.
Should you require a refill with a hydraulic oil other than the one used, please contact the sup-
plier regarding miscibility.
Use only hydraulic oils of the specified "ISO VG46" viscosity (note safety data sheet on the
CD).
NOTICE!
Danger of equipment damage to clamping unit from residual oil!
In closed state the clamping unit contains residual oil. When the volume of oil
as per type plate is filled, too much oil will be inside the hydraulic system. Sub-
sequent mold opening will cause significant equipment damage to hydraulic
oil components.
If the clamping unit is closed, fill only to the minimum mark in the sight glass.
51
Procedure for hydraulic oil filling:

1. Open the filler cap on the oil tank.
2. Only use a filling device fitted with a depth/fine filter with a filter mesh of < 10 µm- that
complies with ISO 16889 to fill the oil tank:
 Use only HLP46 hydraulic oils that meet standard DIN 51524-2 to fill the oil tank.
 Permissible degree of soiling/purity as per ISO 4406:1999 <=17/15/11.
 The oil fill level must be in the top third of the sight glass while the clamping unit is
open, but in the bottom third when the clamping unit is closed!
3. Close oil tank filling aperture with filler cap.
4. Vent hydraulic system.

13 Vent the pump

A small delivery rate and speed is prescribed for a gentle start of the hydraulic fixed displace-
ment pump.
The ’vent the pump’ program is activated either automatically via the control unit or manually
by the service technician. Owing to the reasons covered by guarantee, pump venting is logged
in the control unit.
 Automatic activation:
 When commissioning
 When the oil level switch responds
 Manual activation:
 When commissioning at the customer's location
 After changing a pump
 After an oil change
NOTICE!
Use of an unvented pump will damage the pump system.
Vent the pump as per the instructions when commissioning it.
Venting procedure:
1. Install a suitable hose with leakage oil reservoir on the miniature measuring point on or
in the proximity of the pump according to the hydraulics schematic.
[1] Fixed displacement pump
[2] miniature measuring point
2 [3] Leakage oil reservoir
2. Wait until there is some oil in the oil leakage container.

This may take up to 30 minutes depending on the design.
53
3. Also loosen the bleeder screw on Voith pumps until oil discharges. Air is thereby able to
escape more quickly. Then re-tighten.
4. Change to the ’set-up’ mode.

5. Set the ’Pump venting mode’ variable to ’Yes’ in the ’Pump x’ list of variables.
 Display of the ’pump venting mode =>set-up mode’
6. Select the pump to be vented with the ’Start venting outputs for pump no. (0=off)’ vari-
able.
NOTICE!
Risk of damage! Ensure that there is some oil in the oil leakage container before
motor start. This means that there is oil in the pump space, and the pump is not
dry when running.
7. Start the venting with the Motor ON/OFF switch.

CAUTION!
Hydraulic oil may discharge abruptly from the venting line! Arrange for suit-
able safety measures.
 Display of the ’venting of pump x active’

8. Vent until oil discharges without bubbles at the measuring hose.
9. End the venting with the ’Start venting outputs for pump no. (0=off)’ variable or with
motor ON/OFF key.
10. Remove the miniature measuring hose.
Effects when ’vent the pump’ active:
Alarms
Pump venting mode => set-up mode

Pump venting mode (oil level) => set-up mode
Cause Activation of the ’vent the pump’program.
Effect Motor start possible only in the set-up mode
Remedy Automatically after switching off pump venting
Venting Pumpx active
Cause Pump venting was started
Remedy After oil discharges without bubbles, switch off pump venting

Parameters in the variables monitor
typ. value
Variables group: Pump 1 Long text Level
Unit,
Pump1.sv_bPumpVentilationMode Pump venting mode 11
Pump1.sv_iVentilationPumpUnitId Start venting releases for pump no. (0=off) 11
Pump1.sv_rPumpVentilationV Volume venting the pump 12
Pump1.sv_rPumpVentilationP Vent pump pressure 12
55
14 Vent hydraulic system

The hydraulic oil system must be bled after connecting and start-up.
How to detect air in the hydraulic system:

 Bubbling
 Jerky functional movements of clamping and injection unit
 Abnormal noises
Venting procedure:
1. Set maximum stroke and low values for pressure and speed (ca 20%) for functional
movements.
2. Run the machine through a complete stroke in set-up mode - 8 to 10 times in each case:
 Mold - opening/closing
 Ejector - advance/retract
 Nozzle - forward/return
 Injection/Screw retraction
3. After completing the venting process, check the hydraulic oil level and top up with
hydraulic oil if needed!
Oil level too low
Cause Hydraulic oil level too low.
Effect Motor stop, heating reduces to standby, alarm message.
Remedy Fill up with hydraulic oil, and repair any leakages.

15 Cleaning after installation

Perform basic cleaning after the installation.
! CAUTION!
Skin damage from undiluted detergent!
Undiluted detergent can damage the skin by degreasing it or from an alkaline
pH value.
While cleaning the injection molding machine, wear appropriate protective
clothing (e.g. gloves, face protection, ...).
Dilute the detergent with water based on the degree of contamination of the
injection molding machine.
NOTICE!
Risk of injury due to incorrect cleaning!
The injection molding machine can become severely damaged due to missing
or improper cleaning.
Follow the cleaning notes below when cleaning.
Cleaning notes
 Use only soft cleaning rags for cleaning; never use wire wool or hard objects.
 Clean the bare and painted metal parts with the Tarco Super or Christ Lacke paint
cleaner 968 detergents.
 Slightly oil all bare metal parts with the Cortec Corshield VPCL - 369 rust inhibitor after
cleaning.
 Clean all Plexiglas covers, pictograms and signs with warm water and adding a mild
detergent.
Never use concentrated disinfectants or solvents such as: Sagrotan, Lysoform, ethyl
alcohol, acetone, or other alcoholic liquids.
Information
If the cleaning agent or preserving agent mentioned in the cleaning instructions is not avail-
able, then an equivalent substitute must be used. For more detailed information - see the
safety data sheet.
57
16 Connections
The connection of media lines to the injection molding machine is described in the Connection
chapter.
NOTICE!
When laying out media lines, ensure that unlimited operation of the injection
molding machine is possible and that nothing is damaged.
Connection overview of an injection molding machine.
[1] Machine type plate

[2] Main switch
[3] Mains connection
[4] Connection cooling water return
[5] Connection cooling water feed

16.1 Electrical connections
! WARNING!
Danger of fatal injury due to high voltage!
A qualified electrician is required to connect the machine to the mains power
supply.
Always observe your power distributor's regulations.
Pay attention to:

 Foundation plans
 Circuit diagram (in control cabinet)
 Direction of rotation mains connector (clockwise!)
 Rating plate on the inside of the heavy current cabinet door
Check IP protection type for the injection molding machine's electric/electronic cabinet 54.
The power line must be routed through the wiring terminals in the electric/electronic cabinet to
the main terminals and connected to them!
Connection and main fuse according to circuit diagram.
You can connect the machine to a TN-C network or to a TN-S network.
2 4 6 N1 14 2 4 6 N1 14
-Q11 -Q11
1 3 5 N 13 1 3 5 N 13
` `
` `
PE
PE
L1 L2 L3 PEN L1 L2 L3 N PE
TN-C network TN-S network
When connecting to a TN-C network , the PE conductor must be connected to the N conduc-
tor at the mains connection!
59
Check clockwise rotary field main connection

All three-phase loads of the injection molding machine with a clockwise rotary field were con-
nected at the manufacturing facility.
1. Connect the rotary field measuring instrument with measuring lines to the main termi-
nals.
2. The rotary field measuring instrument displays the rotary field direction.
3. With an anticlockwise rotary field make a phase change.
Rotary field measuring instru-
Connector sockets
Anticlockwise rotary field

Right rotary field
16.2 Network connection

A network connection is located at the rear of the monitor to connect the machine with the site
network.
Ethernet interface for a network connection of the machine:
[1] Ethernet interface on rear side of

monitor (RJ45 jack).
Network connection interrupted
Cause poor network quality, defective cable, no network connection
Remedy check network, check network cable

16.3 Cooling water

Depending on the machine type, cooling water may be required for:
 Oil cooling, for cooling hydraulic oil, for hydraulics unit
 Flow controller (barrel infeed area, mold heating)
 Temperature control devices
 Water-cooled servomotors
NOTICE!
Risk of damage by insufficient water quality!
If water specifications are not maintained, the cooling system may be damaged
by deposits or corrosion.
Use water treatment systems to treat the cooling water.
Cooling with flowing water from the public supply network is not recommended.
A flexible connection to the supply line is required (use appropriate hose connectors). Note
connectors for feed and return flow!
Observe correct positions and connection dimensions for the cooling water connections in
foundation plans.
Information
If the water temperature is exceeded, the integrated monitoring can cause a production inter-
ruption.
Water temperature:
 Water infeed temperature max. 25 °C (77 °F) for standard machines
 Water inlet temperature max. 32 °C (90 °F) for machines with enhanced cooling perfor-
mance
 Input pressure 3-5 bar (44-73 psi)
 Pressure differential between flow and return min. 1.5 bar (22 psi)
Cooling water quality:
The water must be clear, colorless and inodorous as well as free from algae, germs, fungi,
bacteria, iron, manganese, hydrogen sulfides, floating matter, suspended matter and sedi-
ments.
We cannot give any warranty concerning the durability of parts that come into contact with
cooling water as the aggressivity of the water depends on many factors.
Information
If the following values are unknown, or not adhered to, consult a hydro-technology expert to
obtain detailed analysis. The consultant will be able to suggest suitable approaches as
needed.
61
Requirements for water quality in the table must be satisfied:
Water constituents Concentration
pH value 7- 8,5
Electric conductivity < 500 µS/cm
Total hardness < 6 dH
Chloride < 30 mg/l
Sulfations < 50 mg/l
Suspended matter / particles < 25 µm
Ammonium < 2 mg/l
Iron (dissolved) < 0,5 mg/l
Manganese (dissolved) < 0,05 mg/l
Copper < 0,1 mg/l
Oxygen dissolved at 25 °C < 0,1 mg/l
Potassium permanganate con- < 100 mg/l

sumption
Undissolved, settleable solids < 0,1 mg/l
Free carbonic acid < 15 mg/l
Total bacteria count < 1000 K/ml
Oil Avoid, oil-free

16.4 e-flomo
ENGEL e-flomo is a system for mold cooling and temperature control. The e-flomo manifolds
measure, monitor, document and control temperature control parameters.
1 2
[1] Type plate

[2] Electronic box number
Type plate information

 Manufacturer's works
 Type designation flow controller
 Engel Material number
 Serial number of the e-flomo
 Year of construction
 Weight
 Power supply and rated current
Temperature control medium
Description Value
Temperature control medium Water, corresponding to water specifi-

cation
Permissible temperature control 120 °C (248 °F)

temperature, Maximum
Permissible temperature control 5 °C (41 °F)

temperature, Minimum
Permissible media pressure, 10 bar (145 psi)

Maximum
Due to the design of the hose system (e-flomo supply, hoses between e-flomo and mold etc.),
the maximum permissible media pressure can be at low values and the maximum permissible
temperature control water temperature can be at lower temperatures.
Information
The e-flomo mold connection hoses are not part of Engel's scope of supply.
63
16.4.1 Cooling water connection

Observe correct positions and connection dimensions for the cooling water connections in
foundation plans.
Observe connection for advance and return!
Connections
Description Value
Connection for water intake 1" internal thread
Connection for water supply 1/2" internal thread
! WARNING!
Danger due to high temperature and pressure on temperature control water
manifold!
Hot fluids under pressure can cause serious injury and burns to the eyes and
skin.
Hot surfaces can cause serious burns to the skin.
Perform servicing and maintenance work only in cold and pressureless state!
1 2
3

[3] Connection for mold cooling circuit flow line
[4] Connection for mold cooling circuit return line

Check e-flomo x water supply manifold x
Cause Pressure on the cooling water return line is higher than the cooling
water flow because the flow and return flow have been connected
incorrectly.
Effect Process malfunction (no production stop)
Remedy Correct the connections on the flow and return flow line.
The forward pressure alarm delay can be set in the Variables monitor
in the EFlomo1 group of variables, see Technical Manual.
65
16.4.2 Electrical connections

The electrical connections from the e-flomo to the injection molding machine, for connecting a
further e-flomo and for connecting to the power supply are located in the electronics box.
The labeling shows on the electronics box shows where the individual connections are located
for the connections of the sensors and valves in the electronics box.
[See Labeling electronics box on page 261.]
Connections e-flomo
[1] 4-pin circular connector

to connect to the power supply
[2] 8-pin round socket RS 485 OUT
For the connection of additional flomo manifolds or electronic connector
[3] 8-pin round socket RS 485 IN
To connect to the control unit or to the upstream e-flomo manifold

Connection example
Return
Advance
e-flomo 1
24 V
Power pack Return
Advance
e-flomo 2
Return
Advance
e-flomo 3
67
16.5 Compressed air supply (maintenance unit)

For machines with pneumatically actuated equipment, an air filter unit is required.
! WARNING!
Danger of injury due to damage high-pressure lines!
All pipelines on the plant must be checked for their work-safe state at least
quarterly.
NOTICE!
Danger of damage due to air valves clogging!
Use only oil-free compressed air. (For compressed air quality see following
specifications)
The compressed air line must be of the same dimensions as the maintenance unit it services.
If a smaller line is used, pressure to the system may be inadequate.
The installation direction is marked with an arrow (flow direction).
Supply pressure max. 10 bar from the unit to the maintenance unit
Max. (1 MPa)
max. (145 psi)
Operating pressure to be set 6 bar from the maintenance unit up to the

(0.6 MPa) last consumer
(87 psi)
[1] Handwheel operating pressure

[2] Manual shut-off valve
[3] Manometer
[4] Filter tray

[5] Display for the condensate level

(Maximum fill height)
[6] Condensate drain (orange button)
The pneumatic system must provide a compressed air quality that complies with the following
specification:
ISO/DIN 8573-1 Quality class Values
Residual oil content 4 5 mg/m³
Residual dust content 3

Part size 5 µm
Part density 5 mg/m³
Residual water content 4 6 g/m³

(at pressure dew point DPT) 3° C
Installation:
If possible, mount at the point with the highest pressure and the lowest temperature (near the
consumer).
At the connection observe arrow for flow direction on controller housing.
Observe temperature and pressure limits. Build in reservoir axis vertically.
Close the opposite, not used connection.
Commissioning:
Lift the handwheel from its latched-in position up to the stop, then turn to the left, and allow to
latch in again. Switch on the compressed air supply.
Setting of the operating pressure:

Static (no air flow) or dynamic (during operation of downstream consumers). Lift the operating
pressure handwheel from its latched-in position and turn to the right until the desired operating
pressure has been reached, then allow to latch in again.
Lowering the set pressure:

Lift the handwheel from its latched-in position and turn counterclockwise until the operating
pressure has dropped below the new set value, then set the new pressure by turning clock-
wise, and allow it to latch in again.
See also maintenance instructions in chapter: [See Pneumatic on page 240.]
69
16.5.1 Compressed air monitoring

The operating pressure is monitored by a pressure switch, (like the switch for step safety on
DUO machines, etc.).
This sensor is built in between the maintenance unit and the compressed air line.
Connection cable
Adjusting screw
Pressure scale
The switching point for the pressure switch is set with the adjustment screw and is set to moni-
tor the operating pressure.
Message when the operating pressure is not reached:
Compressed air monitoring machine circuit x
Cause There is either no or not enough compressed air being supplied to the
circuit.
Remedy Establish compressed air supply to circuit x, check the air mainte-
nance unit and pressure switch

17 Commissioning
Before switching the machine on, check that all transport safeguards have been removed, and
that all installation and connection tasks have been performed correctly.
! WARNING!
Failure to follow instructions for commissioning may lead to fatal injury!
Do not commission the injection molding machine unless you have ensured
that:
All fixed and moving covers on the injection molding machine have been cor-
rectly screwed down and are closed.
The plant is ready for use, and complies with safety regulations.
There are no persons in the machine's danger area.
17.1 Commissioning the injection molding machine

Procedure for commissioning following setup and connection of the injection molding
machine.
1. Check that no people are inside the safety guarding of the machine.
2. Close the safety gates.
3. Switch on main switch.
Main switch
71
4. Press the ON/OFF key.
ON/OFF key
Emergency stop button
Machine motor switch
Program interruption key
5. After start up of control unit switch on compressed air at the maintenance unit.
6. Secure the cooling water supply.
7. Check functions of the security equipments.
[See Maintenance of the safety devices on page 182.]
8. Select screen ’Alarms’.
9. Check and, if necessary, eliminate the alarms.
10. Acknowledge alarms with the program interruption key.
11. Switch on the machine motor.
12. Further instructions on controlling and operating the injection molding machine:
see Operator manual

17.2 Serviceapplication
You can manage machine software, operating system and backup files as well as view log files
and create status reports in the Service Application.
The ’Service application’ is accessed through the screen page ’System Administration’:
screen page
System administration
The screen page is below the following components and tasks:
Components Tasks
System settings
does not exist
User logout Trigger status report Trigger crash report
Serviceapplication Change PDF files for Help Write configuration
NOTICE!
Software unfit for production due to incorrect settings!
Some settings in the Service Application are only intended for ENGEL person-
nel or may only be changed upon instruction by ENGEL Service. Changing
these settings may damage the machine software and make the injection mold-
ing machine incapable of production.
Observe the notes in the individual chapters and follow the instructions of
ENGEL Service.
73
17.2.1 Screen structure

The Service Application is fully controllable at the touchscreen. If a keypad is required for an
entry, a screen keypad will appear after touching the relevant field.
Serial No.: Network: User level:

2IP address: Network drive: Host name:
3 Basic functions System administration Service Software management
41 Basic functions
Basic software functions, reports and user administration
Status report User administration Backup Update

5
612 Backup
7 Backup write Restore backup
12.1 Backup write

8Safety copies of machine-specific software components and data sets have been created
NOTICE!
9 Write machine, parts and configuration data prior to writing a backup!
Target drive
10
Backup
11No target drive selected
[1] Quitting the service application

[2] Info bar
Display of the serial number, network information and user level of the logged-on user.
[3] Main menu
The active menu item is highlighted
[4] Explanation for the active main menu item
[5] Function menu
[6] Unique numbering and explanation for the function menu item
[7] Sub-function menu
[8] Unique numbering and explanation for the sub-function menu item
[9] Setting hints
[10] Setting range
Area in which the settings of the active function/sub-function are made.
[11] Message area

Info bar
The info bar is always visible and displays the serial number of the injection molding machine,
network information and user level of the logged-on user.
Serial No.: Network: User level:

IP address: Network drive: Host name:
 Serial No.
The serial number of the injection molding machine with control index.
 Network
A screen flag shows the status of the network connection. A green screen flag indicates
a functioning network connection, while a red screen flag indicates that no network con-
nection is established.
 User level
Display of the user level of the logged-on user. When starting the machine with a prob-
lem in the machine visualization, the service application starts in English with user level
13.
 IP address
The control unit displays the IP address when a network connection is established.
 Network drive
A screen flag shows the status of the network drive. A green screen flag indicates a con-
nected network drive, while a red screen flag indicates that no network drive is con-
nected.
 Host name
Display of the control unit's host name in the network.
Main menu
The main menu is always visible and serves as a preselection for the individual functions.
Basic functions System administration Service Software management
1 Basic functions
 Basic functions
 System administration
Functions for the system administration
 Service
Functions for ENGEL commissioning engineer
 Software management
Advanced functions for the software management
75
Function menu
The function menu allows you to select the individual functions of the Service Application.
Each function has a unique number. Many functions are divided into sub-functions for the sake
of clarity. Functions can occur in several main menu items, although the number of sub-func-
tions can differ depending on the main menu item.
Example: Basic functions
1 Status report User administration Backup Update
2 12 Backup
3 Backup write Restore backup
12.1 Backup write

4 Safety copies of machine-specific software components and data sets have been created
[1] Function menu

[2] Number and designation of the selected function
[3] Sub-function menu
[4] Number and designation of the selected sub-function
Setting range
After having selected the required function, you can perform the required settings in the setting
range.
The Service Application issues status messages, indications and warnings in the lower area of
the setting range.
Example: Write backup

12.1 Backup write
Safety copies of machine-specific software components and data sets have been created
NOTICE!
Write machine, parts and configuration data prior to writing a backup!
Target drive
Backup
No target drive selected

Keyboard
Many functions require text or numbers to be entered. The keypad opens when you touch the
relevant field.
1Network address 2
[1] Title bar with designation of the input field in which the entry is made
[2] Closing the keypad and canceling the entry
[3] Keypad layout switchover
77
17.2.2 Functions
17.2.2.1 Reports
You can create a ’Status report’ in order to provide ENGEL Service with the required informa-
tion in case of an error. This contains the typically required information and, because of the lim-
ited file size, can be sent via e-mail to ENGEL Service.
The ’Crash report’ is an extended ’Status report’ with additional information. The ’Crash report’
may only be created after it is requested by ENGEL Service and can be several 100 MB large.
10 Reports
Create status reports and crash reports
Target drive
Status report (~ 10 MB) Crash report (~ 100 MB)
Status report Crash report
Create report
1. Open function menu item ’Reports’.
2. Select target drive for the report.
3. To write a status report, press [Status report].
To write a crash report, press [Crash report].
 The progress is displayed in the message area. After successfully writing the report,
the message ’Status report was written successfully’ or ’Crash report was written
successfully’appears.

17.2.2.2 Backup
You can create or restore backups of the machine-specific software components and data
sets. You can typically use a USB memory stick or an enabled network drive as a storage loca-
tion.
The following menu items are located in the sub-function menu:

 Backup write
creates a backup of the machine packages and the stored data sets.
 Restore backup
Restoring software with a backup
 Delivery backup
Create a delivery backup.
Information
Write machine and parts data before writing a backup!
Creating a backup
Backup write
12.1 Backup write

Create and manage backups of the machine-specific software components and data sets
NOTICE!
Write machine, parts and configuration data prior to writing a backup!
Target drive
Backup
1. Select ’Write backup’.

2. Select target drive for the backup.
3. To write the backup, press [Backup].
 The progress is displayed in the message area. After a successful backup, the mes-
sage ’Backup was written successfully’appears.
 The name of the backup file contains the date of the backup, the serial number and
whether it involves a machine or robot backup.
79
Restoring a backup
Information
Machine and parts data present in the machine are overwritten.
Restore backup
12.2 Restore backup

Restoration of the machine-specific software components and data sets from existing backup files
NOTICE!
Restoring a backup requires a restart of the control unit upon leaving the service applica-
tion.
Subsequently read in machinery, parts, and configuration data again!
Source for backup
Restoration list
Restore backup
1. Select ’Restore backup’.

2. Select the storage location for the backup in the ’Source for backup’ selection list.
 The restoration list is loaded with backups available at the location where saved.
3. Select the required backup in the restoration list.
4. Press [Restore backup].
 The progress is displayed in the message area. After a successful backup, the mes-
sage ’Restore backup was performed successfully’appears.
Delivery backup
NOTICE!
Danger of data loss!
Settings are reset at the control unit for a delivery backup.
Only make a delivery backup if you were expressly prompted to do so by
ENGEL Service.

17.2.2.3 Software packages

Depending on the main menu, the software package management contains the functions for
updating, installing or uninstalling and repairing software packages.

 Update
Updating software packages. The machine may not be in automatic mode for updating
the software.
 Management
Installing and uninstalling software packages.
 Restore
Repairing incorrectly installed software packages.
Information
Write machine and parts data before updating, installing, uninstalling or repairing software
packages!
Update software packages
Update
13.1 Updating software packages

Update and manage software packages
NOTICE!
Write machine, parts and configuration data prior to the software update!
The control unit needs to be restarted when quitting the Service Application after a software update.
Updatable software packages
Update all software packages Update the selected software packages
Update all Update
1. Select ’Update’.
2. Select the source for updates in the selection list.
 The list with updatable software packages in the source is loaded.
3. To update an individual software package, select the required software package in the
list and press [Update].
4. To update all updatable software packages, press [Update all].
 The progress is displayed in the message area. After a successful update, the mes-
sage ’Software update was performed successfully’appears.
5. Restart the control unit so that the update becomes effective.
81
Install or uninstall software packages
Management / Software packages
13.2 Software package management

Administrate software packages
NOTICE!
Write machine, parts and configuration data prior to the software update!
Installation or uninstallation requires a restart of the control unit upon leaving the service application.
Selection of software package type
SINGLE
Available software packages Installed software packages
Install Re-install Uninstall
Software packages have been loaded
1. Select ’Management’ or ’Software packages’.

2. Select the type of software package in the selection list.
 Startup
Software package for commissioning by ENGEL.
 Meta
Software package consisting of several individual packages.
 Single
Individual software packages, e. g. e-help
 System
System packages. These cannot be modified.
3. Select the required software package for installation in the ’Available software pack-
ages’ column.
Press[Install].
 The installation is executed. The progress is displayed in the message area.
4. In order to re-install software packages that have already been installed, select the
desired packages in the ’Installed software packages’ column.
Press[Re-install].
 The installation is executed. The progress is displayed in the message area.
5. Select the required software package for uninstalling in the ’Installed software pack-
ages’ column.
Press[Uninstall].
 The uninstall process is executed. The progress is displayed in the message area.
6. Restart the control unit so that the changes become effective.

Repair software packages

It is possible to repair software packages from user level 13 and higher.
NOTICE!
The control unit can malfunction if settings are made incorrectly when repair-
ing software.
Only perform steps for repairing software if you were expressly prompted to do
so by ENGEL Service.
Restore
13.3 Repairing software packages

Repairing incorrectly installed software packages.
Source for software package
Accept
NOTICE!
The control unit needs to be restarted when quitting the Service Application after repairing the software
package.
Command for repairing the software package
Accept
1. Select ’Repair’.
2. Select the source for the software package after instruction by ENGEL Service.
Press[Accept].
3. Select the command for repairing the software package according to instruction by
ENGEL Service.
Press[Accept].
 The repair is executed. The progress is displayed in the message area.
83
Alarms
Internal error occurred: Wrong cube-version -> contact ENGEL
Cause The required Cube Flash version is not installed.
Effect none
Remedy None: Please contact Engel Customer Service.
Internal error occurred: Wrong kecontrol-version -> contact

ENGEL
Cause The correct kebian system version is not installed.
Effect none
Remedy None: Please contact Engel Customer Service.
License expires in x days
Cause A time-limited software function runs out.
Effect After the time elapses, the control unit deactivates the corresponding
software function.
Remedy Request a new license from ENGEL and load it onto the control unit
via ’Update software packages’.

17.2.2.4 Data administration

You can view log files and delete data that are no longer needed in the data management.

 Log files
Allows viewing of log files
 e-help
Deletion of redundant manuals from the e-help
 Data folder
Deletion of redundant data from the machine's data folder
Log files
The log files record all processes that are processed by the control unit. When troubleshoot-
ing, these files help in the root cause analysis. If you require assistance in interpreting the log
files, please contact ENGEL service.
Log files
18.1 Log files

Overview of the log files for the control unit
Log files selection
85
e-help
The e-help screen page is used for displaying and deleting installed manuals.
e-help
18.2 . Managing the manuals

Overview and deletion of manuals in the control unit
Installed manuals
Delete
1. Select the manuals to be deleted according to instruction by ENGEL Service.

Press[Delete].
 The manuals are deleted and displayed in the message area.

Data folder
The data folder's contents include protocols, and machine and parts data stored on the
machine. Files that are no longer needed can be deleted on this screen page as required.
NOTICE!
Danger of data loss!
Deleted data cannot be restored.
Ensure before deleting that the data are no longer needed.
Data folder
18.3 Data folder

Overview and deletion of folders and files (e. g. protocols, machine and parts data sets) in the machine's data folder
Selection of files Last change Size Attributes
Delete
1. Select ’Data folder’.

2. Select the desired files for deletion.
Press[Delete].
 The files are deleted and displayed in the message area.
17.2.2.5 System information

With the system information you can view system protocols.
87
 Performance
Display of the running processes and system resources
 Storage location
Overview of the memory on the hard disk
 Network configuration
Displaying the current network configuration
 Network drive
Display network drive configuration
Example:
Performance
Overview of the performance data

17.2.2.6 User administration

Users created on the control unit can be exported and this saved data is imported to other
machines again.
11 User administration
Import and export user data.
NOTICE!
Importing user data requires a restart of the control unit upon leaving the service application!
Source for user data
Importable users Exportable users
Service_Customer
Teach_L1
Teach_L3
Importing Export
Importing or exporting users

1. Open function menu item ’User administration’.
2. In the selection list ’Source for user data’ , select the storage location to which the users
are to be exported or from which users are to be imported.
3. Highlight the users who are to be exported or imported in the list.
4. To write the user data, press [Import] or [Export].
89
17.2.2.7 Date and time

The date and time for Austria were already set by ENGEL when first commissioning the injec-
tion molding machine. After installing the machine in your country, you have to adjust the time
zone in the ’Date and time’ function menu item. The setting automatically changes over from
summer to winter time and vice versa based on the country selection.
NOTICE!
A date or time change back into the past can make the control unit unfit for
production.
Only change the time zone. If a time correction back into the past is neverthe-
less necessary, please contact ENGEL Service.
14 Time zone, date and time

Set time zone, date and time
NOTICE!
The control unit needs to be restarted when quitting the service application after changing the time
zone.
Changing the date or time causes an immediate shut down of the control unit.
Set time zone: Europe/Vienna Date and time

Time zone selection
Accept Accept
1. Open ’Date and time’ function menu item.

2. Select time zone in the list, e.g. Europe, Berlin.
3. Press [Accept] to confirm the change.
Optional date and time change

1. Set year, month and day in the calendar.
2. Set the time in the selection lists using the format ’Hours:Minutes:Seconds’ (24-hour
clock), e.g. 14:25:16 (= 2:25 p.m.).

17.2.2.8 Network configuration

To be able to store backups or parts data on a network drive or retrieve these from there, the
network must be setup first.

 Change
Adjust network configuration and set up network drive
Restore network settings
 Displays
Displaying the current network configuration
Change network configuration
Change
15.1 Change network configuration

Adjust network configuration and set up network drive.
NOTE! The control unit needs to be restarted when quitting the service application after
changing the network configuration.
Configuration file selection Network interface
Configuration of the network interfaces
Automatically start interface
Network type
IP address
Subnet mask
Network broadcast
Network gateway
Name server 1
Name server 2
DNS search
Accept Cancel
1. Select ’Change’.
 Configuration file selection
When selecting a configuration file, the selection option appears for network inter-
faces that were saved in the configuration file. These network interfaces can be
edited. If you change the network settings, then the control unit creates a backup of
the last settings. This backup can be used to restore data after an incorrect setting.
 Network interface
Set the selected network interface.
 Automatically start the network interface
If the screen switch is ticked, the network interface is configured when the control
unit starts. If the screen switch is not ticked, the network interface is not active.
91
2. Adjust network configuration.

 Network type
Select either ’static’ (static IP address) or ’dhcp’ (automatically assigned IP address).
Also fill out the other fields in the ’static’ setting.
 IP address
The IP address to be assigned to the machine.
Do not use internal control unit addresses 192.168.100.1 and 192.168.100.10!
 Subnet mask
Subnet mask, usually 255.255.255.0
 Network broadcast
If necessary, indication of a broadcast address
 Network gateway
IP-address of the gateway in the network
 Name server
The IP-address of the name server in the network can also be left blank.
 DNS search
If necessary, indication of a DNS server in the network
Press[Cancel] to not save the change.
Display network configuration

The configured network interfaces are displayed.
Displays
6.2 Display network configuration

Display of the current network configuration by using ifconfig

17.2.2.9 Network drive

In order to be able to store data on a network drive or access data on a network drive, a net-
work drive must be also connected in addition to the network settings.
Before you can connect network drive on the machine, you must create a folder on the network
drive containing the serial number of the machine; this, in turn, contains a folder with the con-
trol index. The serial number and control index are located on the control unit, on the ’Software
information’screen page.
Example:
Released folder ’Machines’ with a folder for a machine with the serial number 177391 and the
control index 1.

 Change
Allows network drives to be modified or added.
 Displays
Shows configured network drives.
Change
16.1 Adjust network drive configuration

Adjust network drive configuration.
Server drives selection
Adjust network drive configuration
Server name
Share name
User name
Password
Domains
Parameters
Accept Cancel
 Server drives selection

Selection of server drives already configured. Selecting nothing to add a network drive
in the selection.
 Server name
Server on which the released folder is set up. ’Server name’ can be the IP address or
the domain name.
93
 Share name
Share name for the folder at the server
 User name
User name for logging in to the network drive
 Password
Password for logging in to the network drive
 Domains
Domain of the network drive
 Parameters
Additional parameters that might be necessary for integrating the network drive.
Add network drive

2. Leave ’Server drives selection’ empty.
3. Fill in fields for configuration of the network drive.
Change network drive

2. Select server drive from the selection list.
 The configuration of the network drive is loaded.
3. Adjust configuration.

Indicates the configuration of the network drive if this was recognized.
Displays
7.2 Display network drive configuration


17.2.2.10 Start-up mode
NOTICE!
Incorrect settings in commissioning mode!
Commissioning mode can only be deactivated again by ENGEL Service. Acti-
vation of commissioning mode by operating personnel can lead to serious
incorrect setting.
Only switch on if you were expressly prompted to do so by ENGEL Service.
95
17.3 Venting a pressure pad

After installation, the pressure pads must be vented to remove any air pockets.
Entrapped air
Maximum tiebar position
Minimum tie-bar position

screen page
Mold height
By default, you can find the screen page in the following components and tasks:
Components Tasks
Conversion
Initial sampling
Production settings
Mold components
Tie bar positions
Determine locking positions automatically
Calibrated mold height 0,0 mm

tie-bar Calib. Set val. Act Locking pos. Individual lock- Valve
mm
1 0,0 10,00 0,0
mm
2 0,0 10,00 0,0
mm
3 0,0 10,00 0,0
mm
4 0,0 10,00 0,0
Push buttons
Tie-bar adjustment larger
Tie-bar adjustment smaller
Procedure
1. Close mold (do not build up clamp force).
3. Select first tie-bar using the ’Individual adjustment’ screen switch.
4. Use the pushbuttons to move 2-3 times to the minimum and maximum tie-bar position.
5. Deselect the tie-bar using the ’Individual adjustment’ screen switch.
6. Perform steps 3 and 4 for every tie-bar.
 All pressure pads are vented.
97
17.4 Temperature control device

The temperature control device is a device with the task of maintaining a liquid, the so-called
temperature control medium, at a constant temperature.
! CAUTION!
Danger of burning!
Escaping tempering medium and hot pipes can cause burns.
Check temperature control devices and connection pipes for correct condition
and leaks.
Wear protective clothing.
The devices heat or cool a temperature control medium. There are two different types of tem-
perature control devices available, using water or diathermic oil.

Setting up for injection
The barrel, screw and nozzle need to be adjusted to match the injection mold for some injec-
tion molding processes.
! WARNING!
Risk of injury! Risk of burns from heated components!
The heated barrel and high pressure molten material can cause severe eye
injuries and skin burns.
Always wear suitable protective clothing when working on the barrel (e.g. heat
protection gloves, face protection, etc.). The processing material may not be
under pressure.
Information
Observe the following, before working on the nozzle, screw, and plasticizing barrel:
1. Heat barrel to operating temperature.

2. Clean the barrel with a suitable cleaning agent and purge.
99
1 Nozzle centricity
Nozzle centricity must be checked at maintenance interval 3, after leveling the machine, or
replacing the barrel.
Readjustment is required when:

 The nozzle position is outside of centering tolerance.
Centering tolerance: max. 0.2mm (0.01 in).
 The nozzle moves laterally or vertically when building up contact pressure at the injec-
tion mold.
Testing situation for nozzle centricity:

 Injection mold: dismounted.
 Barrel: temperature approx. 200° C (390° F)
 Nozzle position at same level as mounting surface
Needed tools
Allen key
Heat protection gloves
Wrench
Caliper
Frame water level
Straight edge

Measuring positions nozzle centering

1
[1] Measuring position horizontal (same distance between nozzle and mold centering)
[2] Measuring position vertical (same distance between nozzle and mold centering)
[3] Stationary platen
Procedure for injection unit 860 - 2460
Adjusting the vertical nozzle position

The injection unit must be at a central position for adjustment without contact pressure.
1. Loosen the 2 Allen screws to loosen both fastening flanges.
Retaining flange
Allen screws
101
2. Loosen the nut on barrel support on the operator side. Back up the tread roller on the
non-operator side using the eccentric tappet.
Tread roller
Tappet
Nut
Material cylinder support
3. Loosen the Allen screws at the front and rear of the swiveling unit.
 The eccentric shafts' clamping was released.
Swivelling unit
Allen screw
eccentric shaft

4. Adjust the nozzle's vertical position by rotating the front and rear eccentric shafts. Posi-
tion the nozzle approx. 0.2 mm (0.01 in) below the center.
Nozzle
eccentric shaft
5. Set the tappet on the non-operator side so that the tread roller makes contact and the
nozzle is centered.
Tappet
Nut
6. Following centering, tighten the nut on the barrel support on the operator side.
103
7. Tighten the Allen screws at the front and rear of the swiveling unit.
 The eccentric shafts were clamped.
Swivelling unit
Allen screw
eccentric shaft
8. Tighten the Allen screws at the mounting flanges.
Retaining flange
Allen screws
9. Advance and retract the nozzle multiple times to check centering.

10. If necessary, repeat the adjustment.
 The nozzle was successfully centered vertically.

Adjust the nozzle position to the left or right

The injection unit must be at a central position for adjustment without contact pressure.
1. Loosen the 2 Allen screws to loosen both fastening flanges.
Retaining flange
Allen screws
2. Loosen the Allen screw at the barrel support and release the tappet (also on the oppo-
site side).
Tappet
Allen screw
105
3. Loosen the counter nuts on the grub screws.
Headless pins
Counter nuts
4. Adjust the nozzle by turning the grub screws left or right. Ensure that the nozzle axis is
square to the mounting face.
Nozzle
Headless pins

5. Following centering, position the eccentric tappets so that they are in contact with the
guide rail and tighten using the Allen screws.
Tappet
Allen screws
6. Fasten the injection unit by the grub screws and tighten the counter nuts.
Headless pins
Counter nuts
107
7. Tighten the Allen screws at the mounting flanges.
Retaining flange
Allen screws
8. Advance and retract the nozzle multiple times to check centering.

9. If necessary, repeat the adjustment.
 The nozzle was successfully centered.
The setup process can cause the injection unit to twist at the end of the nozzle stroke (stop
position of hydraulic piston).
If needed, adjust the rear piston rod:
1. Loosen counter nut.
Counter nut
Piston rod
2. Using a wrench, turn the piston rod until the stop position of the nozzle contact cylinders
is even.
3. Tighten counter nut.
4. Check nozzle centering and re-adjust if necessary.

2 Mount mold
Correct mounting of the injection mold helps to ensure optimum operations and greatly
reduces wear and tear.
Note the following additional information:

 Drawing [See Mold mounting dimensions on page 279.]
 Operator manual: Clamping unit chapter
 Information by mold manufacturer on mold weight, fixing system, cooling system, mold
heating, media connectors etc.
! WARNING!
Danger due to hot barrel and pressurized molten material!
Danger of serious eye injury and burns to skin.
Observe the following items:
 Wear suitable protective clothing and face protector.

 Ensure that the process material is pressureless.
! WARNING!
Danger of crushing with oversized injection molds!
Molds are not permitted to extend over the edges of the machine's mold fixing
platen.
Information
Danger of damage to mold mounting platen and injection mold!
 Adjust the mold height and mount the mold in ’Setup’ mode.
 Maximum permissible tolerance for mounting surface parallelism on injection mold: 0.1
mm/m (0.001 in/ft).
 Make sure the injection mold is adequately fixed!
The fastening screws must reach at least 1.5 x thread diameter into the tapped bore on
the mold fixing platen!
 Use injection molds with a minimum side length of (s). Use of molds that are too small
can cause excessive surface pressure.
109
Correctly and incorrectly mounted molds

To make best-possible use of a mold, and reduce wear and tear, both mold halves must be
mounted concentrically.
Misalignment of the mold halves increases wear and tear, and as a consequence will typically
cause wear and tear on inserts and cores.
As gravity acts in the vertical plane, the vertical alignment of the mold halves is particularly
important. As a general rule, you should attempt to achieve a misalignment of less than 0.05
mm (0.002 in). At 0.1 mm (0.004 in) or more you will typically hear some knocking on immers-
ing the guides, and some wear and tear of the tie-bars can occur. On large-capacity machines
misalignment can be far higher without causing any problems.
Wrong Wrong
Correct
3 2
[1] Correctly mounted mold:

Both mold halves are mounted on the mold fixing platen facing each other concentri-
cally.
[2] Incorrectly mounted mold:
The ejector side is mounted too high with respect to the nozzle-side mold half.
[3] Incorrectly mounted mold:

The ejector side is mounted too low with respect to the nozzle-side mold half.

2.1 Correct crane lifting of molds
! DANGER!
No standing under suspended loads. Transportation must be performed by
skilled staff familiar with transportation of machines.
2.1.1 Attach both mold halves at the same time
1 2 3 4 5
Mold halves pulled Mold halves of Molds not cen- Mold halves Flexible rope or
towards each different weights tered mounted sepa- crane scales
other by rod rately
[1] When fitting both mold halves at the same time, use a rod to connect. Make sure the rod
does not displace the relative center of the two mold halves. If in doubt, mount the two
mold halves separately.
[2] If the two mold halves are of different weights, use a heavy-duty rod, and attach as
closely as possible above the center of gravity of each mold half.
[3] The lifting eye must be exactly above the center of gravity of the mold to allow the crane
to lift it as vertically as possible Always avoid lifting at an angle so that the top is flush
with the fixing platen you need to mount, but with a gap at the under side. Slight skew in
the other direction is not so serious, since you can compensate for this by skewing
slightly by lifting with the crane towards the fixing platen, until you can fit the mold com-
pletely flush.
[4] Do not mount the two mold halves separately as the separating line has to be com-
pletely closed.
[5] Use the crane to provide best possible support to the mold when mounting at center of
the mold fixing platen. You cannot position the mold to a hundredth of a millimeter using
the crane. Make sure you have a flexible connection between the crane hook and the
lifting eye (e.g. synthetic rope). However, crane scales are your best option. Crane
scales will ensure that you lift exactly the weight of the mold, and that the mold can be
mounted on the machine without any gravitational effect. The heavier the mold, the
more important it is to use crane scales. In case of heavy molds, always use crane
scales - use of crane scales for lighter molds is not a disadvantage.
111
2.1.2 Attach each mold half individually
1 2 3 4 5
Individual mold Center the If required, use First mold half Use crane
halves crane above a spacer (with centering scales to mount
mounted off the load, and pin) mounted the second mold
center avoid oblique conventionally half
pull
[1] Attach individual halves exactly above point of gravity to ensure vertical lifting by crane.
[2] When mounting the mold, position the crane exactly above the central axis of the mold
fixing platens. Oblique pull twists the mold and must be avoided.
[3] If the fastening thread is not exactly above the mold's center of gravity, fit a spacer.
[4] Mount the mold half with the centering pin first; this is typically the nozzle side, or the
rotary table side for rotary tables. You can lift the first mold half to be mounted in the nor-
mal way. The mold half is positioned above the centering pin, and there is no need to
take the mold weight into consideration. A flexible rope or crane scales give you an
advantage.
[5] The second mold half to be fitted typically does not have a centering pin, or only sup-
ports rough centering. When the mold closes, and the guide bolts are inserted, the lifting
force exerted by the crane lifting the mold half should be equal to the mold weight as far
as possible. Exerting too little lifting force, or none at all, causes the deadweight of the
mold to act on the guide bolts, and this can cause misalignment and play. In this case,
the mold half mounting position would be too low. Exerting too great a lifting force could
cause the rope to break, or cause the mold half to be mounted at too high a position.
Crane scales give you the ability to lift with precisely the deadweight of the mold half.
Read off the weight value before inserting the guide bolts. After closing the mold, but
before building up clamping and compression force, raise or lower the crane until the
crane shows exactly the weight value shown previously.
The heavier the mold, the more important it is to use crane scales. In case of heavy
molds over 200 kg (440 lb) always use crane scales - use of crane scales for lighter
molds is not a disadvantage.

2.2 Correct centering of mold
2.2.1 Standard applications
Standard applications, cen-

tered on nozzle side
A standard mold is normally centered on the nozzle side. The diameter of the centering pin on
the mold is normally 0.1 mm (0.004 in) smaller than the centering bore on the mold fixing
platen.
Centering is NOT required ejector side. As a mounting aid, you can also fit a centering pin that
is at least 0.5 mm (0.02 in) smaller on this side for individual mounting of mold halves.
2.2.2 Heavy molds

In case of heavy molds over 200 kg (440 lb) use crane scales for mounting. Without crane
scales it is very difficult to mount heavy mold halves concentrically to one another. Thus, it may
make sense to finely adjust both halves.
Information
If you decided to center both halves, you must ensure that both centering pins on the mold
are mutually true to a precision of less than 0.05 mm (0.002 in).
In this case the centering diameters of the two mold fixing platens on the machine must be
exactly true. ENGEL injection molding machine are true to < 0.1 mm (< 0.004 in) coaxially as
a factory standard. If you require greater precision, please specify this requirement with your
order.
Special case for tie-barless machines: If the max. permitted mold tilting torque on the ejec-
tor side (weight of the ejector-side mold half times the distance to the center of gravity - see
instruction manual) is exceeded, an additional support is required.
This consists of 2 additional guide shoes (one each on the operator and non-operator sides)
including supporting brackets which are either fitted to the mold surface on the moving mold
fixing platen, or directly to the moving mold half. The adjusting spindles screwed through the
supporting brackets rest on the top of the guide shoes. They cannot be connected to them as
the moving mold fixing platen, and thus the additional supports, need to lift off the guide shoes
when clamp force is built up. Set the spindles without building up clamp force, at setup pres-
sure with the mold closed. Only slightly pre-tighten the spindles. The moving mold fixing platen
is not permitted to tilt back. Check platen parallelism if needed.
113
2.2.3 Special applications

In some cases it is necessary to decide which side to center, however, the following basic prin-
ciples must be observed in all cases:
Always perform precision centering on the side where the greatest degree of accuracy is
required. Under normal circumstances, this will be the nozzle side, as the nozzle needs to hit
the nozzle contact position as precisely as possible.
If a drive or swiveling unit, e.g. a ’X-comp’ that is integrated in one of the two mold fixing plat-
ens is used, mold centering must also be at this side.
2.2.4 Mold anti-twist safeguard (rotational centering)

An anti-twist device for the mold is to be positioned on the side where mold centering (fine
adjustment) is located.
For a rotary table, you may need to position an anti-twist device for the mold rotary table side.
As the rotary table side mold half must be mounted first, if you mount the mold halves individ-
ually, it is impossible to adjust its rotation to match the nozzle side mold half.

2.3 Correct mounting the mold
! DANGER!
Transport and mounting of molds may only be done by skilled staff who are
familiar with these tasks.
2.3.1 Mounting of both mold halves

Procedure:
1. Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray).
GREASE
2. Use a rod to connect the mold halves and mount jointly on machine. Align with the mold
fixing platen where the (more exact) centering lug of the mold is located; this is normally
the nozzle side Make sure that you lift the mold vertically with the crane. Always avoid
lifting at an angle so that the top is flush with the fixing platen you need to mount, but
with a gap at the underside. Slight skew in the other direction is not so serious, as you
can compensate for this by skewing slightly on lifting with the crane towards the fixing
platen, until you can fit the mold completely flush.
3. Insert the centering pin into the centering bore on the mold fixing platen. Adjust the mold
rotation using a spirit level if needed, and tighten this side while the mold is still being
supported by the crane.
115
4. Close the moving mold fixing platen in setup mode, and ascertain the mold height.
Leave the mold attached to the crane.
5. Then build up and relieve the clamp force about 3 times, but without opening the mold;
simply relieve the clamp force. Building up and relieving the clamp force allows for pre-
cise mutual alignment of the mold halves in the µm range. Make sure the lifting force
exerted by the crane exactly matches the dead weight of the mold. Then exert the clamp
force.
6. With clamp force built up, tighten the ejector-side mold clamping screws. The formula
for minimum reach of screws is: Screw diameter x 1.5. The property class of the screws
should be 8.8 or 10.9 Harder screws can mean danger to the mold fixing thread espe-
cially in the case of cast mold fixing platens. If using a high speed mold mounting device
build up clamp force before moving in the tensioning wedges.
7. Remove the crane and the rod, you can then open and close the mold, and start opera-
tions.

2.3.2 Mounting of individual mold halves

Procedure:
1. Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray).
GREASE
2. Move the mold half with the more precise centering pin into the machine and align flush
with the mold fixing platen. This is normally the nozzle side. Make sure that you lift the
mold vertically with the crane. Always avoid lifting at an angle so that the top is flush with
the fixing platen you need to mount, but with a gap at the under side. Slight skew in the
other direction is not so serious, as you can compensate for this by skewing slightly on
lifting with the crane towards the fixing platen, until you can fit the mold completely flush
Insert the centering pin into the centering bore on the mold fixing platen. Adjust the mold
rotation using a spirit level if needed, and tighten this side while the mold is still being
supported by the crane If rotational centering (anti-twist safeguard) is envisaged, it must
also be fitted at this side.
3. Use the crane, and preferably crane scales, to move the second mold half into the
machine, and align precisely with the second (typically ejector-side) mold fixing platen.
4. Close the moving mold fixing platen in setup mode, move crane to match the clamping
movement, and ascertain mold height. Make sure the weight value shown on the crane
scales does not change when inserting the guide rods, otherwise raise or lower the
crane slightly.
117
5. Then build up and relieve the clamp force about 3 times, but without opening the mold;
simply relieve the clamp force. Building up and relieving the clamp force allows for pre-
cise mutual alignment of the mold halves in the µm range. Make sure the lifting force
exerted by the crane exactly matches the dead weight of the mold. On tie-barless
machines, the display on the crane scales changes lightly due to frame deformation and
the accompanying lifting of the moving mold fixing platen from the guide rails when the
clamp force is built up. This effect is slightly greater on the ejector side mold half than
on the nozzle side.
6. With clamp force built up, tighten the ejector-side mold clamping screws. The formula
for minimum reach of screws is: Screw diameter x 1.5. The property class of the screws
should be 8.8 or 10.9 Harder screws can mean danger to the mold fixing thread espe-
cially in the case of cast mold fixing platens. If using a high speed mold mounting device
build up clamp force before moving in the tensioning wedges.
7. Remove the crane and the rod, you can then open and close the mold, and start opera-
tions.
2.3.3 Factors affecting mold performance
1 2 3 4
Different temperatures High operating Unparallel insulat- Eccentrically
of mold halves temperature ing platens arranged cavities

[1] Different temperatures of the two mold halves lead to different heat expansion, and thus
to different dimensions. This can cause more wear and tear, and misalignment of the
injection molded parts at the parting line.
[2] In the case of high mold temperatures, the non-centered mold half can be caused to
become uncentered during the warm-up phase. This is caused by heat expansion,
especially in case of asymmetric alignment of fixing points. This would result in coaxial
displacement of the two mold halves. In this case, it is necessary to attach the non-cen-
tered half with the crane again after heating up and to lift it as precisely as possible.
Then loosen the clamping screws for this half, and repeat the mounting procedure start-
ing at the step of building up and releasing the clamp force 3 times.
[3] Ensure true parallelism and constant wall thickness of any insulating platens used.
Deviations of >0.05 mm (>0.002 in) cause uneven distribution of pressure in the mold,
and can lead to overmolding and formation of burrs on the injection molded parts. Insu-
lating platens are subject to wear and tear. Always check parallelism and wall thickness
- especially if problems occur.
[4] Eccentric alignment of cavities requires more clamp force. The further cavities in an
asymmetric layout are from the center, the more clamp force is required to prevent over-
molding. Thus, when designing the mold, attempt to arrange cavities symmetrically and
close to the center.
119
2.4 Checking the coaxiality of the two mold halves

The coaxiality of the two mold halves is fairly easy to check using the following method. For
this purpose, you need to attach 3 magnetic holders with dial gauges to the outside of the mold
half with the centering bore (not the centering pin).
Procedure:
1. Close the mounted mold halves to a point where the centering pin is about to enter the
centering bore; do not allow the two to touch. Measure the vertical parallelism of the
platens operator side. The distance of the measuring points must be approximately the
distance from the end of the guide pin to the center of the (front) guide shoe (length a).
Note the parallelism values you measured.
2. Attach one magnetic holder directly above each of the two top guide bores To measure
the lateral displacement, attach a magnetic holder to the side of the top guide bore. The
following figures assume that the bores are in the ejector side mold half. If the bores are
on the nozzle side, you must also attach magnetic holders nozzle side. Then align the
dial gages with the top of the pin which is close to being inserted, and set the display to
zero.
Detailed drawing:
Guide pins not yet
inserted
3. Close the mold in set-up mode to a point where the guide pins are inserted into the
guide holes Make sure the feelers on the dial gages do not rest in a lubrication groove
on the guide pins. Now read off the dial gage. Detract the parallelism value from the
value you read off the two top dial gages, or add the value, depending on the platen par-
allelism direction (narrower or wider at the top).
Detailed drawing:
Guide pins inserted

Example:
The top gages show a value of +0.1 mm (+0.004 in) after entering the hole. The sensor is
’pressed in’ , which means that the pins are being lifted, which in turn means that the mold
half with the bores (the ejector side in this case) is too high. If platen parallelism was 0.03 mm
(0.0012 in) higher at the top than at the bottom, you would need to subtract the 0.03 mm
(0.0012 in) from the insertion value of 0.1 mm (0.004 in) that you measured. This would result
in a vertical displacement of 0.07 mm (0.0025 in) caused by mounting. A value of less than
0.05 mm (0.002 in) would be okay; wear and tear to the tie-bars can occur for displacements
of 0.1 mm (0.004 in) or more. On large-capacity machines the displacement value can be far
higher without causing any problems.
121
2.5 Influencing factors of the injection molding machine on mold clo-

sing behavior
Different clamping mechanisms of injection molding machines can have a different influence
on the closing behavior of the mold. Among others, the following items are important:
 Good platen parallelism of the machine is important for clean, wear-free closing of the
mold. Upon clamp force build-up the mold halves align on the mold parting surface, with
good platen parallelism tilting is less than with poor platen parallelism.
 The rigidity of the frame has an effect on the straightness of the guides and thus on the
straightness of the closing movement. Under the load of a heavy moving mold half a soft
frame will be more severely deformed than a very rigid frame.
 The accuracy of the concentricity of the center holes in the mold fixing platens plays an
important role in centering on both sides of the mold.
Inspecting the clamping mechanism
ENGEL DUO machine
ENGEL large-scale machines are of 2-platen design and are known as

DUO machines. Platen parallelism and concentricity of the center holes are also adjustable on
this machine type via the adjustable support of the moving mold fixing platen. The machine
frame is supported on a large number of extremely stable machine shoes. Particularly long
support on the rigid guide rail ensures the precise and tilt-free movement of the moving mold
fixing platen.
Information
Independently of the machine type used, it is important to mount the two mold halves as con-
centrically as possible to one another.

2.6 Blow out cooling water

The pneumatic mold purging (blowing out molds) is possible via e-flomo manifolds.
! WARNING!
manifold!
skin.
NOTICE!
Risk of damage to the rotating union!
Contaminated cooling circuits of the injection mold (e. g. rust or deposits) can
damage the rotating union.
Thoroughly flush and preserve all cooling circuits before dismantling the injec-
tion mold.
NOTICE!
The sensors installed in e-flomo are sensitive to pressure shocks.
Fill and empty the manifold slowly.
Purge at max. 4 bar (58 psi) air pressure.
123
e-flomo manifold
1 2
3

[3] Connection for mold cooling circuit flow line
[4] Connection for mold cooling circuit return line
Procedure
1. Shut off water supply to the e-flomo and switch off e-flomo at the control.
2. Connect central advance flow of the e-flomo to the compressed air supply.
The compressed air can also be fed into a hose or pipe line upstream the central supply.
Take steps to prevent air from entering the water supply when purging, e.g. Closing the
shut-off valves.
3. Direct central return flow into a collecting tank or drain.
4. For e-flomo with manual shut-off valves:
Open advance valves in the circuits that are to be blown out.
5. Change to operating mode ’Valve position control’ :
Set the circuits that are to be blown out to a valve opening degree of 30 %.
6. Slowly open the pressurized air valve in the feed line.
NOTICE!
Risk of damage! Avoid pressure shocks and water hammering while purging.
7. Close pressurized air valve again after the blowout process.

8. Switch off the e-flomo again.
9. For e-flomo with manual shut-off valves:
Close flow valves again.
10. Restore water supply for the mold temperature control.

3 Setting up the barrel

The following points describe how to dismantle and mount the nozzle, barrel and screw on the
injection unit.
Use only original ENGEL barrels, nozzles and spare parts.
! WARNING!
Risk of falling when working above heights of 1.0 m (39.4 in)!
This can result in serious personal injury!
Use a suitable mounting aid for work above 1.0 m (39.4 in). If you need to use a
mounting aid, use equipment that complies with local safety regulations and
prevents falling, tripping or slipping.
! WARNING!
Danger of crushing due to moving components!
Risk of crushing during machine movements and work during the conversion
process.
Never enter or reach into the movement range of the components.
! CAUTION!
Risk of burns from heated components!
The heated barrel and high pressure molten material can cause severe eye
injuries and skin burns.
Always wear suitable protective clothing when working on the barrel (e.g. heat
protection gloves, face protection, etc.).
NOTICE!
Danger of damage to equipment due to improper settings!
Exceeding the maximum allowable operating temperature of the barrel
(+350 °C or 662 °F) may damage the screw and the barrel.
If the temperature is exceeded, a written permission must be procured from the
manufacturing firm ENGEL.
125
Observe the following, before working on the nozzle, screw, and plasticizing barrel:
1. Heat barrel to operating temperature.
2. Clean the barrel with a suitable cleaning agent and purge.
3. For special designs, note the drawing of the barrel in the Spare parts chapter.
Example: Injection unit 860 - 2460

1 2 3 4 5
9 8 7 6
[1] Nozzle with nozzle heater and thermocouple

[2] Flange with fastening screws
[3] Barrel with barrel heating elements and thermocouple
[4] Barrel ring nut
[5] Screw coupling
[6] Clamping lever for injection unit
[7] Hydraulic injection cylinder
[8] Pull rod
[9] Material cylinder support

4 Remove barrel
For adjustment of the shot volume or for cleaning (e. g. material switch) it is required to change
or remove and refit the barrel.
! DANGER!
No standing under suspended loads. Transportation can only be performed by
trained staff familiar with transportation of machines.
The lifting gear's angle of inclination must be at least 45°.
! WARNING!
Risk of falling when working above heights of 1.0 m (39.4 in)!
Use a suitable mounting aid for work above 1.0 m (39.4 in). If you need to use a
mounting aid, use equipment that complies with local safety regulations and
prevents falling, tripping or slipping.
! WARNING!
Danger of crushing in the screw coupling area and barrel anchoring points!
Do not reach into this area while functional motions are in progress.
Set low speeds for all injection unit movements.
127
Removing the barrel

1. Heat the barrel and nozzle up to operating temperature.
2. If the barrel has not yet been cleaned, clean the barrel:
 depending on the processing material use appropriate cleaning material following
vendor's instructions for cleaning material.
 Retract the nozzle until the material can flow freely onto the splash plate.
Return nozzle
 Function:
Screw injection
Plasticizing
Repeat frequently until only cleaning material exits the barrel. Then purge.
3. Advance the nozzle as far as possible without building up pressure
Advance nozzle
4. To uncouple the screw, retract the screw to halfway through the plasticizing stroke.
+ Consent key + screw retraction
5. Switch off motor.

6. Unlock both locks and remove the screw cover.
Screw cover
Lock
7. Install the screw cover and lock it using the locks.

8. Switch on motor.
9. Advance screw to max. position.
Screw injection
10. Move screw coupling away from screw.
+ Consent key + screw retraction
11. Switch off motor.

12. Unlock both locks and remove the screw cover.

13. Loosen the locking grub screw and turn the clamp collar approx. 1/2 turn anticlockwise.
Safety setscrew
Clamping ring
14. Open the locking mechanism by unscrewing the hex screw to the stop.
Locking mechanism
hexagon bolt
15. Uncouple injection unit by removing bolts.

16. Manually retract the injection unit a sufficient distance and clamp in place with clamping
lever.
CAUTION!
Danger of burns! Heated up barrel!
Clamping lever
129
17. Loosen the 6 Allen screws on the underside of the injection unit.
Allen screws
18. Swivel out the injection unit on the operator side.

19. Switch off barrel heating or temperature control device.
20. Remove the caps using an Allen key.
Covering caps

21. Install ring nuts.
ring nut
22. Use 2 ring nuts to attach barrel to suitable lifting gear.

DANGER!
Risk of fatal injury! The lifting gear's angle of inclination must be at least 45°!
Keep the lifting gear tightly fastened!
> 45°
> 45°
23. Switch off barrel heating or temperature control device.

24. Loosen existing media connections to the barrel.
25. If needed, use an assembly aid to manually push the barrel out of the screw coupling
area.
26. Use lifting gear to carefully pull the barrel away from the injection unit.
131
27. Position the barrel onto the guide rail and adjustable foot.
Guide rail Adjusting foot
 The barrel was successfully removed.

5 Install barrel
Basically follows the same steps as for disassembly but in reverse order.
NOTICE!
Danger of damage to equipment from installed ring nut!
The front ring nut damages the nozzle guard during advancing of the injection
unit.
Remove the front ring nut after completion of barrel installation.
NOTICE!
Danger of damage to equipment from incorrectly installed split ring!
Incorrect installation causes damages to the screw, the coupling and leads to
process instabilities. There must be no axial play on the screw.
Correctly re-install the split ring of the screw.
133
6 Changing a nozzle
For some molds you need to fit a special nozzle instead of the standard nozzle.
Needed tools
Allen key
Wrench
Dismantling the nozzle

1. Heat the barrel and nozzle up to operating temperature.
2. If you have not cleaned the barrel yet, then start cleaning:
 Retract the nozzle until the material can flow freely onto the splash plate.
Return nozzle
 depending on the processing material use appropriate cleaning material following

vendor's instructions for cleaning material.
 Function:
Screw injection
Plasticizing
Repeat frequently until only cleaning material exits the barrel. Then purge.
3. Retract the injection unit to the maximum nozzle stroke.
Return nozzle
4. Switch off the machine motor.

Ensure that all function movements are blocked.
5. Set the nozzle heater set value to 0°C (32 °F).
 Nozzle heater was switched off.
Set value 0,0

pos. tolerance
neg. tolerance
Minimum monitoring

6. Remove the Allen screw and slide the nozzle strip heater from the nozzle.
WARNING!
Danger of falling! Working above heights of 1.0 m (39.4 in)!
CAUTION!
Danger of burns! Heated components!
Allen screw
Nozzle heater band
7. Slide the thermocouple from the nozzle.

Thermosensor
8. Unscrew the nozzle using a torque wrench.
Nozzle
 The nozzle has been successfully dismounted.
135
Mounting the nozzle

1. Clean the thread and sealing surface on the flange using a brass brush.
Flange
Sealing face
Thread
2. Clean the nozzle thread and nozzle surface using a brass brush.
Nozzle thread
Nozzle surface
3. To facilitate renewed disassembly, apply temperature resistant lubricant or a Teflon strip

to the nozzle thread.
Thermoplastic, Duroplastic and PVC machines
Use a lubricant with a temperature resistance of 600 °C (1112 °F).
For example: Loctite 8150 Anti-Seize.
4. Screw the nozzle all the way into the flange up to the stop without tightening it.
Flange
Nozzle
5. Slide the thermocouple onto the nozzle.
Thermosensor

6. Slide the nozzle strip heater onto the nozzle and fasten it using the Allen screw. Tighten
the Allen screw to the specified torque. [Siehe Anziehdrehmoment auf Seite 726.]
Allen screw
Nozzle heater band
7. Switch on the nozzle heating.

CAUTION!
8. After the nozzle and barrel have reached operating temperature, tighten the nozzle.
[Siehe Anziehdrehmoment Düse auf Seite 727.]
 The nozzle has been successfully mounted.
137
Tightening torque nozzle
Nozzle thread Dimension tightening torque
M 28 x 1,5 200 Nm (150 lbf ft)
M 45 x 3 500 Nm (370 lbf ft)
M 55 x 3 800 Nm (590 lbf ft)
M 98 x 6 1700 Nm (1250 lbf ft)
Tightening torque Nozzle strip heater and strip heater
Glow plug heating elements

Application temperature up to 350 °C (662 °F)
Allen screws tightening torque

Minimum rigidity 8.8
M5 6 Nm (4.4 lbf ft)
M6 11 Nm (8.1 lbf ft)
M8 18 Nm (13.3 lbf ft)
Ceramic heating elements

Application temperature up to 450 °C (842 °F)
Allen screws tightening torque


7 Removal of barrel flange

For certain tasks it is necessary to remove the barrel flange.
Needed tools
Allen key
Torque wrench
139
Steps in removing the flange

1. Heat the barrel and nozzle up to the operating temperature.
2. Retract the injection unit to the maximum nozzle stroke.
Return nozzle
3. Switch off the machine motor.

Ensure that all function movements are blocked!
4. Subsequently switch off nozzle heater and first barrel heater zone.
Set value 0,0 0,0

pos. tolerance
neg. tolerance
Minimum monitoring
5. Remove nozzle strip heater with thermocouple and first barrel strip heater.
WARNING!
Danger of falling! Working above heights of 1.0 m (39.4 in)!
CAUTION!
Cylinder heater band
Thermosensor
Nozzle heater band

6. The barrel flange is attached with Allen screws. Loosen the Allen screws crosswise.
 The flange has been removed.
Loosening sequence:
1
5
4
8
7 3 6 2
141
Steps in installing the flange

1. Clean sealing surfaces of flange.
Sealing
face
2. Place flange and tighten Allen screws step by step:

 Use a torque wrench to tighten the 4 Allen screws crosswise to 50% of the specified
torque.
 Starting at the front tighten the 4 Allen screws crosswise to 100% of the specified
torque.
Tightening sequence:
3 2
3. Tighten the remaining Allen screws crosswise to 100% of the specified torque.
 The flange has been installed.

Allen screw tightening torque
Allen screw 10.9 tightening torque
M8 25 Nm (18 lbf ft)
M 10 48 Nm (35 lbf ft)
M 12 83 Nm (61 lbf ft)
M 16 202 Nm (149 lbf ft)
M 20 370 Nm (272 lbf ft)
M 24 660 Nm (486 lbf ft)
M 30 1300 Nm (958 lbf ft)
M 36 2300 Nm (1696 lbf ft)
M 42 3600 Nm (2655 lbf ft)
M 48 5400 Nm (3982 lbf ft)
M 10 57 Nm (42 lbf ft)
M 12 97 Nm (72 lbf ft)
M 16 236 Nm (174 lbf ft)
M 20 440 Nm (324 lbf ft)
M 24 790 Nm (582 lbf ft)
M 30 1600 Nm (1180 lbf ft)
M 36 2700 Nm (1991 lbf ft)
M 42 4300 Nm (3171 lbf ft)
M 48 6500 Nm (4794 lbf ft)
143
Tightening torque heater band

Maximum application temperature of the medium to be heated = 350° C (662° F).
DIN compliant screws912 Pretensioning in cold state

M6 11 Nm (8.1 lbf ft)
M8 18 Nm (13.3 lbf ft)

Maximum application temperature of the medium to be heated 450 °C (842 °F).


8 Barrel cleaning
To remove material residues and contaminants, it is necessary to disassemble the barrel and
clean the individual components.
Conditions before cleaning the barrel:

 Barrel heated up to operating temperature
 Barrel removed
Dismantle the barrel

1. Place the barrel on a suitable surface. Secure it against tipping over.
CAUTION!
2. Remove barrel flange with nozzle. [See Removal of barrel flange on page 139.]
3. Clean the barrel.
 Clean the flange's sealing surface with a brass-wire brush.
 Clean the inside of the barrel with a cleaning cloth soaked in detergent (e. g. Tun-
clean 895 made by Tunap)
Sealing face
4. Insert the screw horizontally into the vice with the tip facing the vice (brass or aluminum
clips).
145
5. Dismantle return flow shut-off device.

Non-return valve key
6. Disassemble the non-return valve.
Peak Locking Thrust collar

ring
7. Clean the still warm non-return valve with a brass-wire brush. Remove coarse dirt using
a brass chisel.

Assemble the barrel

1. Clean the screw tip thread and contact surface and check for damage.
2. Apply temperature-resistant lubricant to the screw tip thread and the pressure ring sup-
port.
Lubricant temperature resistant: equal to/greater than: 600 °C (1112 °F)
Lubrication type: e. g. Loctite Anti-Seize 8150
3. Assemble the non-return valve and mount.
NOTICE!
Risk of damage! For the screws 15, 18, 20, 22, 25 mm make sure that the wide
side of the locking ring rests against the screw tip front.
Locking ring narrow side
Locking ring wide side
Thread Pressure ring support
4. Tighten the non-return valve. The non-return valve must have the same temperature as
the screw!
Non-return valve key
5. The contact surfaces, Allen screws and threads on the flange must be cleaned before
fitting the flange to the barrel.
6. Apply a temperature resistant lubricant to the thread and head support of the Allen
screws.
Lubricant temperature resistant: equal to/greater than: 600 °C (1112 °F)
Lubrication type: e. g. Loctite Anti-Seize 8150
7. Install barrel flange with nozzle. [See Removal of barrel flange on page 139.]
8. Clean the nozzle surface before fitting the heating elements.
9. Fit nozzle heating element with thermocouple.
147
10. Use a torque wrench to tighten the screws on the heating element, paying attention to
the tightening torque.
Tightening torques barrel flange

Applicable to a maximum temperature of 350 °C (662 °F)
M 10 48 Nm (35 lbf ft)
M 12 83 Nm (61 lbf ft)
M 16 202 Nm (149 lbf ft)
M 20 395 Nm (291 lbf ft)
M 10 57 Nm (42 lbf ft)
M 12 97 Nm (72 lbf ft)
M 16 236 Nm (174 lbf ft)
M 20 462 Nm (341 lbf ft)
Barrel flange Allen screws 40CrMoV47

Applicable to a maximum temperature of 350 °C to 450 °C (662 °F to 842 °F)
Allen screw 10.9 Allen screw tightening torque

12.9 40CrMoV47
M 10 37 Nm (27 lbf ft)
M 12 65 Nm (48 lbf ft)
M 16 155 Nm (114 lbf ft)
M 20 300 Nm (221 lbf ft)

The application temperature of the medium may be up to 350 °C (662 °F).

M6 11 Nm (8.1 lbf ft)
M8 18 Nm (13.3 lbf ft)

Maximum application temperature of the medium to be heated 450 °C (842 °F).

149
9 Nozzle stroke limitation

On machines without injection gate, a stroke limitation in automatic mode allows the nozzle to
retract only far enough to prevent the risk of pinching between barrel and nozzle protection.
With the exception of the working stroke, advancing movements occur at reduced speed of
max. (20 mm/s).
In the case of very long nozzles, a reduction of the adjustable nozzle stroke may occur after
determining the contact point, with the following message:
Nozzle stroke limitation x
Cause Nozzle stroke setting longer than permitted. Danger of crushing!
Effect Automatic reduction of nozzle stroke setting.
When fitting longer barrels it may be necessary to use longer tie-rods for the injection units.
For some open construction injection unit type machines the nozzle contact point may be out-
side the safety limit. Message:
Contact point not within stroke limits
Effect The alarm lamp flashes and the movement stops. Contact point not
determined
Remedy Check nozzle position. Recalibrate only if using longer tie-rods, and
without injection mold.
When fitting shorter barrels it may be necessary to use shorter tie-rods for the injection units.
For some open construction injection unit type machines the nozzle contact point may be out-
side the calibrated zero point. Message:

Nozzle stroke transducer faulty
Effect Movement stops
Remedy Check nozzle position. Recalibrate only if using shorter tie-rods, and
without injection mold.
Pull rods nozzle x too short
Cause Contact force was not able to be built up due to too short pull rods
(z. g. after barrel replacement)
Effect no cycle start due to contact pressure not built up
Retraction of the nozzle, reverse movement of the screw or mold opening can be reduced due
to frame length, e.g. by installing a longer barrel.
Limitations, blocks, monitoring on unit version H:

1. Actual value check:
If the sum of current positions of the nozzle and the screw exceeds the stroke limit of the
nozzle (screw, mold), retracting the nozzle and reversing the screw are interlocked.
2. Set value check:
If the sum of set positions for nozzle stroke (incl. nozzle contact position), metering
stroke (incl. decompression) exceed the stroke limit of the nozzle (screw, mold), retract-
ing the nozzle and reversing the screw are interlocked.
3. A limit switch for limiting the nozzle stroke (screw, mold) on the frame of the unit blocks
nozzle retraction.
This limit switch is a safety limit switch and should normally never be actuated; see 1
and 2.
Limitations, blocks, monitoring on unit version M:

1. Actual value check:
If the sum of current positions of the nozzle and the moving platen (incl. mold height)
exceeds the stroke limit of the nozzle (screw, mold), retracting the nozzle and mold
opening are interlocked.
2. Set value check:
If the sum of set positions for nozzle stroke (incl. nozzle contact position), mold height
and opening stroke exceeds the stroke limit of the nozzle (screw, mold), retracting the
nozzle and mold opening are interlocked.
3. A limit switch for limiting the nozzle stroke (screw, mold) on the frame of the unit blocks
nozzle retraction and mold opening. This limit switch is a safety limit switch, and should
normally never be actuated; see 1 and 2.
151
9.1 Calibrating the nozzle stroke

Ascertain the maximum possible nozzle stroke on calibration.
Example Injection unit contact force built up:
1
2
3
4
5
6
7
[1] Stroke limitation for nozzle, short barrel

[2] Maximum possible mechanical nozzle stroke (tie rods uncoupled))
[3] Nozzle contact position, short barrel
[4] Calibrated nozzle stroke, short barrel
[5] Nozzle contact position, long barrel
[6] Calibrated nozzle stroke, long barrel
[7] Stroke limitation for nozzle, long barrel

Example Injection unit retracted:
1
2
3
4
5
6
7
[1] Stroke limitation for nozzle, short barrel

[2] Maximum possible mechanical nozzle stroke (tie rods uncoupled))
[3] Nozzle contact position, short barrel
[4] Calibrated nozzle stroke, short barrel
[5] Nozzle contact position, long barrel
[6] Calibrated nozzle stroke, long barrel
[7] Stroke limitation for nozzle, long barrel
! WARNING!
Danger of crushing during movements by injection unit!
There is danger of crushing between the barrel and the safety gate, and
between the barrel and the barrel support.
During calibration make sure a mold is not mounted.
Procedure at the calibration:
Information
Access level 11 (Customer Service) is required for calibration. Movements throughout the
whole nozzle stroke up to the mechanical limits of the hydraulic cylinder must be possible.
1. Set machine to manual mode, and close safety gates.

2. Enable calibration by switching from Manual to Input calibrationmode.
153
3. Use the pushbutton to move to maximum stroke, note the actual value on the Nozzle
screen page. After reaching maximum stroke (mechanical stop on hydraulic cylinder),
hold the pushbutton down until the maximum value has been recorded.
4. Use the pushbutton to move in the other direction to minimum stroke, note the actual
value on the Nozzle screen page. After reaching minimum stroke (mechanical stop on
hydraulic cylinder), hold the pushbutton down until the minimum value (0) has been
recorded.
5. Then move back in the other direction. The actual value must match the stroke pre-
cisely.
6. Disable calibration by switching from Input calibration mode to Manualmode.

Maintenance
Maintenance
Regular and carefully performed maintenance of the machine based on the maintenance inter-
vals guarantees:
 Safety of operating staff
 Best possible availability and life-expectancy
 Cost savings
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Perform a visual check of the following items daily, during commissioning and during servicing:
 Good working order of safety devices.
 Check media lines for tightness and signs of wear.
 Check oil level in sight glass.
 Check for sufficient lubrication (e.g. layer of grease, or black stripes on guide rails,
unusual noises, mechanical damage).
 Check the water level in the water separator on the compressed air maintenance unit.
Drain condensation water at approx. 10 mm ( 0.4 in ).
 If available, check lubricant reservoir to ensure sufficient level of lubricant.
Top up if needed. Make sure you use the correct lubricant.
Empty the leakage oil reservoir.
! WARNING!
Danger of fatal injury due to electrical voltage, high pressure, and moving
machine parts!
Maintenance and repair work on the plant may only be carried out by persons
who have been trained for these tasks on ENGEL machines.
Prior to maintenance and repair work, move all vertical movable components
down to the mechanical stop or support them mechanically.
Maintenance and repair work should not be started until the main switch is
switched off and secured against switching on!
 Make sure that electric circuits are powerless before working on them!
 Before working on the pneumatics system, use the hand lever to shut off the supply to
the maintenance unit, and ensure that the unit is pressureless!
 Make sure hydraulic circuit is pressureless before working on it!
 Discharge pressure accumulators!
 Pay attention to cleanliness during all maintenance and repair work!
 Observe general safety and accident prevention regulations!
 Observe the instructions in the chapter Safety!
155
Maintenance
! WARNING!
Danger of fatal injury due to missing gates!
If it is necessary to remove fixed gates to perform maintenance work and
repairs, you are not permitted to operate the machine.
Observe safety instructions before starting work.
After completing maintenance/repairs, always replace the fixed gate and
ensure that it is in the right place!
Use only original spare parts.
ENGEL is not liable in case of:

 use of incorrect utilities
 poor maintenance
 use of third party spare parts
Before commencing maintenance and repair work, check:

 scope of task and effort involved
 Are the required aids available? (tools, devices etc.)
 Required spare parts available?
Contact the service department:

 Your local ENGEL dealer/subsidiary
 The ENGEL works
Information
Take care when disposing of used utilities!
Observe regulations for collecting and disposing of utilities used to run the machine.
They are hazardous to water supplies and can cause severe environmental damage.
Make sure you observe national waste disposal regulations!

Maintenance
1 Maintenance intervals
The control unit shows a digital time scale and a green progress indicator for 4 critical main-
tenance intervals. The last 10% before a maintenance interval has elapsed are shown in yel-
low, the next 10% after the interval has elapsed in red.
screen page
Maintenance intervals
Components Tasks
Maintenance
does not exist
Hours of operation
Total hours of operation
Maintenance interval 1
Days until maintenance
Maximum hours of operation before maintenance required
Maximum hours of operation before maintenance required
Maximum hours before maintenance required
Hours of operation are only counted while the machine motor is switched on.
This maintenance must be carried out at the latest after 1440 operating hours, 500000 cycles,
or after a certain number of kilometers covered by a functional unit (clamping unit, ejector,
screw, nozzle).
The screen displays a percentage value for the current status and the remaining days until the
next maintenance interval (day counter).
Maintenance interval 2, 3
157
Maintenance
Working hours counter. Count only when machine motor is switched on.
Time counter. Counts the hours even when machine is switched off (8760 hours or 1 year)
A warning message signals that a maintenance period has expired:
Maintenance interval x
Cause Maintenance required.
Effect Message only.
Remedy Perform maintenance. Reset the counter by pressing the [R] button.
(access level 10 required).
Check the maintenance interval number to see which tasks are necessary.

Maintenance
1.1 Maintenance schedule

The work mentioned in the table must be carried out after the expiry of the service counter for
the machine and/or after certain hours of operation.
1.1.1 Maintenance interval 1
The following tasks must be carried out according to maintenance inter-

val 1
Cleaning of machine
[See Cleaning of machine on page 164.]
Visual check
Check media lines for tightness and signs of wear Check cables and connec-
tors for signs of damage.
Check safety equipment

[See Maintenance of the safety devices on page 182.]
Perform maintenance on auxiliary devices.

[See Additional equipment on page 285.]
Lubricate guide carriage

[See Lubrication Clamping unit on page 197.]
Lubricate guide carriage

[See Lubrication Injection unit on page 202.]
Lubricate guide carriage - safety gate

Check the maintenance safety gate's function

[See Maintenance safety gate on page 189.]
Perform SCF device SII maintenance

[See MuCell SII on page 175.]
159
Maintenance

val 2
Perform air filter maintenance on control cabinets.

CAUTION: Do not operate without filter
[See Clean air filter on page 166.]
Check that the hydraulic lines are in a safe working condition

[See Hydraulic lines on page 224.]
Perform this task the first time only on reaching

interval 2. Take an oil sample and send it to the oil supplier for analysis. Have
the oil tested for water content and contamination. If needed, filter or change
oil based on manufacturer's recommendation.
[See Hydraulics on page 215.]
Perform SCF device T series maintenance

[See MuCell T series integrated on page 170.]

Maintenance

val 3
Check nozzle centering

[See Setting up for injection on page 99.]
Check pressure accumulator

[See Bladder accumulator on page 235.]
Cleaning of LSR screw

[Siehe Schnecke und LSR Schneckenspitze ausbauen zum Reinigen auf
Seite 720.]
161
Maintenance

val 4
Check sensors and machine accuracy

[See Check machine - Ever-Q on page 163.]
Lubricate fast-closing cylinder

Replace filter element in the venting filter

Change oil of the plasticizing drive

Change hydraulic oil (have the oil checked by your hydraulic oil supplier and
replace oil filter if needed).
[See Change hydraulic oil on page 216.]
Check machine leveling

[See Leveling the injection molding machine on page 43.]
Lubricate tiebar pulling device

Perform SCF device SII maintenance

[See MuCell SII on page 175.]
Clean oil cooler

[See Oil cooler on page 232.]

Maintenance
2 Check machine - Ever-Q

ENGEL has developed a computer-aided test and measuring system in order to check the pre-
cision of critical sensors and functions of the injection molding machine conveniently and reg-
ularly, and to perform calibration as needed.
Sensors are calibrated by performing comparative measurements with calibrated measuring
devices that comply with national standards. Critical technical characteristics of individual sub-
assemblies or sequences are tested under conditions similar to production conditions.
If measured values are outside of set tolerances, correcting measures are initialized. Mea-
sured data is visualized in tables and diagrams, and a test certificate is issued.
Customer benefit
 Checking of sensors in compliance with VDA 6.1-13.3 requirements (QA 9000)
 prevents mold sampling and production with incorrect data
 is a prerequisite for the use of statistical methods for process optimization (e.g. Expert
Control)
 guarantees the retraceability of the process data to national standards
 facilitates the exchange of data between machines
 helps to detect machine errors and wear at an early stage
 represents an important decision making basis for required maintenance
EVER-Q Performance
For new machines EVER-Q can be performed by a trained ENGEL service engineer at the fac-
tory in addition to standard tests. ENGEL recommends a test interval of 1 to max. 3 years,
where subset of all EVER-Q tests is performed annually, or all tests are performed every 3
years.
For more detailed information on EVER-Q contact our main works or your local subsid-
iary's/dealer's service department.
163
Maintenance
3 Cleaning of machine
The best approach to ensuring long life and high precision operations is careful and regular
maintenance of your machine.
! CAUTION!
Skin damage from undiluted detergent!
Undiluted detergent can damage the skin by degreasing it or from an alkaline
pH value.
While cleaning the injection molding machine, wear appropriate protective
clothing (e.g. gloves, face protection, ...).
Dilute the detergent with water based on the degree of contamination of the
injection molding machine.
NOTICE!
Risk of injury due to incorrect cleaning!
The injection molding machine can become severely damaged due to missing
or improper cleaning.
Follow the cleaning notes below when cleaning.
Cleaning notes
 Use only soft cleaning rags for cleaning; never use wire wool or hard objects.
 Clean the bare and painted metal parts with the Tarco Super or Christ Lacke paint
cleaner 968 detergents.
 Slightly oil all bare metal parts with the Cortec Corshield VPCL - 369 rust inhibitor after
cleaning.
 Clean all Plexiglas covers, pictograms and signs with warm water and adding a mild
detergent.
Never use concentrated disinfectants or solvents such as: Sagrotan, Lysoform, ethyl
alcohol, acetone, or other alcoholic liquids.
 If the pictograms are no longer legible, then replace them.
 Clean grease nipples to prevent dirt entering grease cavities during lubrication.
 Keep motors free of dust and dirt deposits to avoid interfering with cooling.
Information
If the cleaning agent or preserving agent mentioned in the cleaning instructions is not avail-
able, then a corresponding substitute must be used. For more detailed information - see the
safety data sheet.

Maintenance
3.1 Cleaning the control panel on the ENGEL control unit
NOTICE!
Danger of operator errors while cleaning the touch screen and controls!
Switch off the control voltage before starting cleaning.
Danger of damage to controls if non-approved cleaning agents are used.
Recommended cleaning agents:

 Standard glass cleaner
 Delothen (plastics cleaner)
We recommend a soft cleaning cloth for cleaning.
Solvent resistance:
The control surface of the ENGEL control unit (C30/controls) is resistant towards the following
solvents:
 Diesel, oil SAE, transmission oil
 Antifreeze (Ethylenglykol)
Exception: Sodium hydroxide - causes slight, white coloring.
165
Maintenance
3.2 Clean air filter

The filter cartridge replacement interval must be determined individually based on dust con-
tamination levels and operating hours. A contaminated filter cartridge will cause the tempera-
ture in the control cabinet to increase!
! WARNING!
Danger of fatal injury due to electrical voltage in the control cabinet!
Do not open the control cabinet to replace or clean the air filter.
Procedure:
1. Switch off the main switch to shut down the fans.
2. Remove louver.
Louver
3. Remove filter mat.
filter element
4. Clean filter cartridge by blowing out with compressed air, or replace.

5. Insert dust-free filter mats.
6. Insert louver.
Louver
 The filter mat has been successfully changed.
NOTICE!
Danger of contamination!
Never run the machine without an air filter!

Maintenance
3.3 Clean cooling water filter

The cooling water filter prevents solids from penetrating into the cooling water system. The
cooling water filter must be cleaned annually, or at shorter intervals depending on the water
quality.
Information
The cooling water filter is located directly downstream of the cooling water supply as stan-
dard. For individual electric drives, the cooling water filter is located directly at the consumer.
Overview:
Cooling water filter
Hexagon socket screw

with dirt guard
Dirt guard with screen
Procedure for screen cleaning

1. Shut off cooling water supply.
2. Remove hexagon socket screw using a wrench.
3. Remove screen from the dirt guard and clean with water. Use a brush for the cleaning.
4. After cleaning insert the screen back in the dirt guard.
5. Mount hexagon socket screw.
6. Restore cooling water supply.
167
Maintenance
3.4 Valve cleaning crossbar cooling
! WARNING!
Risk of burns from the hot crossbar cooling valve.
If a defective valve is detected, then the following message appears:
Barrel heating x Feedthroat x no recognizable temperature

increase
Cause The current temperature of the crossbar has not increased even
though items are being produced.
Effect Alarm lamp
Remedy Check and clean the crossbar cooling valve.
Barrel heating x Feedthroat x recognizable temperature drop
Cause The current temperature of the crossbar has fallen even though there
has been no actuation.
Effect Alarm lamp
Remedy Check and clean the crossbar cooling valve.
Steps for cleaning the crossbar cooling valve:

1. Block ball solenoid.
(Flow of cooling water no longer possible.)
2. Attention: Before removing the solenoid valve, allow the cooling water in the flow
ducts to cool down!
3. Remove the hex bolt using a wrench.
hexagon bolt
Solenoid valve
Phillips screw

Maintenance
4. Remove the four Phillips screws and solenoid valve.
Hexagonal bolt and washer
Solenoid valve
Phillips screws
5. Remove the diaphragm and clean the valve.
Valve head with gasket
Diaphragm
Valve
6. After cleaning the valve, reinsert the diaphragm.

7. Building up the solenoid valve.
8. Turn the ball valve into operation position.
169
Maintenance
4 MuCell maintenance
4.1 MuCell T series integrated

Displays and settings in the ’Maintenance’ tab depend on the type of SCF device.
Maintenance T-100 and T-150

For the SCF devices types T-100 and T-150, the Maintenance screen page for the pump
stroke counter is not available. Observe the manufacturer's data in the instructions for the SCF
device for pump maintenance.
Screen page Maintenance T-200 to T-350

The screen page shows the current cycles and the total cycles for the next booster pump main-
tenance.
Maintenance
Pump 1
Booster pump counters 1 actual value 652
Maximum pump strokes 1 for maintenance 5000000
Booster pump counters 1 total 1001299
Pump x
 Booster pump counters x actual value
Number of pump strokes since the last maintenance or since the value was last reset.
The actual value can be reset from User Level 9 upwards.
 Maximum pump strokes x for maintenance
Number of pump strokes until the next maintenance. The number of maximum pump
strokes for the maintenance is adjustable and can be changed from User Level 11
upwards.
 Booster pump counters x total
Number of total pump strokes by the pump.
Screen page Maintenance T-400

Maintenance
Compressor maintenance
Service check valves done
Oilchange done
Check valves replaced
Pistons and piston rings checked
Condensate bottle emptyed
Change filter
T400 Compressor run hour meter 652 h
Compressor maintenance

Maintenance
If the T-400 compressor hour counter reaches a certain maintenance interval, the screen
flags next to the required maintenance tasks light up. After completion of the maintenance
tasks, tick the screen switch to reset the screen flags. The maintenance tasks are then saved
to the infolog.
During maintenance observe the manufacturer's instructions in the SCF device manual.
Required maintenance tasks:
 Service check valves done
 Oilchange done
 Pistons and piston rings checked
 Change filter
Alarms
MuCellT x: Compressor maintenance required
Cause Maintenance interval reached: maintenance tasks on the compressor

are due.
Effect Alarm message
Remedy Perform the maintenance tasks to prevent damages to the SCF

device.
MuCellT x: pump maintenance required
Cause The number of pump strokes has reached the number of maximum
pump strokes for maintenance.
Remedy pump maintenance required.

Reset the pump stroke counter actual value after pump maintenance.
MuCellT x: Warning Bit 14
Cause The buffer battery in the SCF device will soon fail.
Effect Potential data loss in the SCF device
Remedy Test buffer battery of the SCF device. Follow the manufacturer's infor-
mation for this.
171
Maintenance
MuCellT x: Compressor low oil pressure

(T-400)
Cause Oil pressure outside the tolerance for more than 30 seconds.
Effect Alarm lamp, production stop, motor stop and heating reduction
delayed.
Remedy SCF device: check oil level and inspect compressor. Follow instruc-
tions and review plans of SCF device manufacturer.
MuCellT x: rupture disc broken

(T-400)
Cause No rupture disc OK signal. Rupture disc is broken.
Effect Alarm lamp, production stop, motor stop and heating reduction
delayed.
Remedy Replace rupture disc.

Follow instructions and review plans of SCF device manufacturer.
MuCellT x: Compressor pressure ramp too low

(T-400)
Cause Increase of pressure was too low for 2 minutes.
Remedy Check input pressure.

Check for leaks and correct valve settings: Follow instructions and
review plans of the SCF device manufacturer.
MuCellT x: Compressor high duty cycle - leak

(T-400)
Cause High compressor on-time: there might be a leak.
Remedy Check pipes and hoses for leaks. Follow instructions and review
plans of SCF device manufacturer.
MuCellT x: Compressor high duty cycle - seals

(T-400)
Cause High compressor on-time: seals might be damaged.
Remedy Check compressor seals for wear. Follow instructions and review
plans of SCF device manufacturer.
Check input pressure set value.

Maintenance
MuCell T-Series Test

The Test tab shows the results of the startup test. When starting up the SCF device, a pressure
and system test is carried out as standard.
The startup test can be deactivated in the ’General’ tab, if required.
Test
Start-up test - duration 0,000 s

Flow coefficient 1 calculated 78,000
Flow coefficient 2 calculated 83,000
Start-up test - Boost pressure drop 0,2 bar
Start-up test - pre-metering pressure drop 0,2 bar
Start-up test - delivery pressure drop 0,2 bar
Status SCF device Idling
 Start-up test - duration

Time within which the startup test was carried out.
 Flow coefficient calculated
Flow coefficients calculated during the startup test. A flow coefficient is calculated in
relation to time and line length here. This value must correspond to the flow coefficient
entered in the ’Configuration’ tab. Otherwise an alarm is output.
 Start-up test - Boost pressure drop
Pre-metering pressure drop
Operating pressure drop
A pressure test is carried out during the startup test. The progression of pump, pre-
metering and operating pressure is compared over 1 minute.
 Status SCF device
Displays the operating state of the SCF device.
MuCellT x: System test failed - Wrong flow coefficient set
Cause The flow coefficient calculated during the startup test does not match
the entered value.
Effect Production stop
Remedy Read off the correct flow coefficient from the melt flow element.
Make sure that the correct melt flow element has been installed.
Check the gas line length.
Check whether the pressure test was passed.
MuCellT x: Pressure test failed
Cause The pressure drop was between 4 and 8 bar during the pressure test.
Remedy Check for leaks and, if necessary, remedy.
173
Maintenance
MuCellT x: Pressure test failed
Cause Pressure drop during the pressure test was greater than 8 bar.
Effect Production stop
Remedy Search for leak and, if necessary, remedy.
MuCellT x: Boost pressure too low

MuCellT x: Warning Bit 15
Cause Pumps operating but set value for pump pressure is not attained.
Effect Alarm message, production stop
Remedy Check for leaks downstream of pump.

Check whether air pressure too low.
Pressure transducer of pump is defective: replace.

Maintenance
4.2 MuCell SII

SCF device
Rear side connections Front side without cover
6 8
1
7
3
9
4 10
11
12
[1] SCF drainage valve

[2] SCF outlet to IMM
[3] SCF return from the IMM
[4] Compressed air
[5] SCF gas input (from gas cylinder)
max. 200 bar (2900 psi)
[6] Pressure transducer downstream melt flow element
[7] Automatically actuated drain valve
[8] Manometer high pressure
[9] Melt flow element
[10] Manually operated drainage valve
[11] Low pressure manometer
[12] Pressure transducer upstream melt flow element
The SCF device must be serviced routinely.

 Maintenance interval 1
 semi-annually (duration approx. 6 h)
 Inspection of the SCF device [See chapter Maintenance in the Trexel SCF device
manual]
 System test [See Sequence of system test on page 179.]
 Pressure test [See Sequence of pressure test on page 180.]
175
Maintenance
 Maintenance interval 4
 After 1,000,000 pump strokes, at least annually (duration 2 x approx. 7 h)
 Inspection of the SCF device [See chapter Maintenance in the Trexel SCF device
manual]
 System test [See Sequence of system test on page 179.]
 Pressure test [See Sequence of pressure test on page 180.]
 Replacement of high-pressure pumps [Refer to chapter Maintenance in the Trexel
SCF device manual]
 Replacing the seals on controllers [Refer to the chapter Maintenance in the Trexel
SCF device manual]
NOTICE!
Danger before system standstill from inadequately maintained components.
Carry out system maintenance at the prescribed intervals.
Failure to comply with these instruction may result in serious damage to the
system.
No warranty claims will be recognized for damage due to non-compliance.
The housing cover on the front of the SCF device must be removed for maintenance interval 4.
If the maintenance counter has expired, the alarm and the dialog box appear:
MuCell x: Booster pump 1 maintenance interval reached (per-

form service)
Cause The cycle number has reached the alarm limit.
Effect Alarm lamp
Remedy Carry out maintenance according to manufacturer documentation

and confirm by pressing [Maintenance completed].
Briefly: press [Execute] in the respective dialog box. The counter will
increase by 50,000 pump strokes
CAUTION: Maintenance counter has expired

1:
Maintenance counter for booster pump has expired.

Request a maintenance package from ENGEL and carry out maintenance.
Cancel Help OK

Maintenance
After carrying out maintenance, press [Maintenance completed].
Maintenance
Booster pump 1
Maintenance counter booster pump 1 times
Alarm limit maintenance counter booster pump 1 times
Maintenance completed
Booster pump 2
Maintenance counter booster pump 2 times
Alarm limit maintenance counter booster pump 2 times
Maintenance completed
When [Maintenance completed] is pressed, the following window will appear:

Booster pump maintenance
Maintenance on booster pump carried out!
Confirmation of completion of proper maintenance.

No warranty claims will be recognized for damage due to non-compliance.
Please confirm maintenance on booster pump 1
Cancel Help Execute
Confirming this dialog box and pressing [Execute] will increase the alarm limit by a predeter-
mined value of 1,000,000 pump strokes.
177
Maintenance
Test MuCell Sll

The SCF device must be tested at regular intervals, at least twice a year.
Information
For testing the SCF device for MuCell T-Series Standalone refer to documentation of the
device manufacturer.
On the screen page ’Test’ , you can start the test procedures and read the current status of the
system and the test results.
Test
System test
Start system test

System test active time
Pre-metering pressure
Post-metering pressure
Status of system test Test not active
System test
The purpose of the system test is to check the melt flow element. The required time for the
pressure build-up is determined here. The time is dependent on the built-in melt flow element
(reconciliation with the calibration data sheet).
 Start system test
Screen switch for starting the system test.
 System test active time
Measures the time during the system test. The ’System test active time’ starts as soon
as the pressure has reached 145 bar ( psi) and stops when it reaches 260 bar ( psi).
 Pre-metering pressure
 Post-metering pressure
 Status of system test
’Test not active’, ’Test active’, ’Test completed’, ’Test failed’.
Pressure test
Start pressure test
now
High
For-
After
Pressure test
The purpose of the pressure test is to check for leaks in the system. Following pressure build-
up the pressure is measured and recorded every 15 minutes.
 Start pressure test
Screen switch for starting the pressure test.

Maintenance
 now, 0 - 60
Display of current pressure readings at the respective times.
 High, before, after
Pressure readings ’high’pressure (pump pressure), ’before’ measuring point, ’after’
measuring point
 Pressure test active time
Running time of the current test.
 Status of system test
’Test not active’, ’System under pressure’, ’Pressure built up’, ’Test active’.
Sequence of system test

1. Switch on communication.
2. Feed compressed air to the system.
For information on compressed air quality see chapter ’Compressed air connection’of
the service manual.
3. Check SCF gas supply:
Gaseous N2 or CO2.
Open gas supply and feed gas into the system until a pressure of at least 14.5 bar (210
psi) has been reached. Display ’input pressure’ in the flow chart.
4. Close SCF drainage valve on the rear side of the device (1).
Rear side connections
5
5. Start system test.
System test
Start system test

System test active time
Pre-metering pressure
179
Maintenance
6. In the system test window check that all the items listed have been completed.
System test
Switch on communication.
Feed compressed air to the system.
Check SCF gas supply:
Gaseous N2 or CO2.
Open gas supply and feed gas into the system until a pressure of at least 14.5 bar
(210 psi) has been reached.
Close SCF drainage valve on the rear side of the device.
Start system test.
Note the time.
Everything understood
Cancel Help Execute
7. Tick off ’Everything understood’.

8. Press [Execute].
The test will start. The ’System test active time’ starts as soon as the pressure has
reached 145 bar (2100 psi) and stops when the pressure reaches 260 bar (3770 psi).
9. Note the ’System test active time’ , preferably in the maintenance log.
The readings are comparative values for the next test.
Sequence of pressure test

1. Switch on communication.
2. Feed compressed air to the system.
For information on compressed air quality see chapter ’Compressed air connection’of
the service manual.
3. Check SCF gas supply:
Gaseous N2 or CO2.
Open gas supply and feed gas into the system until a pressure of at least 14.5 bar (210
psi) has been reached. Display ’input pressure’ in the flow chart.
4. Close SCF drainage valve on the rear side of the device (1).
Rear side connections
5
5. Switch off the ’SCF device pressure relief’.

Maintenance
6. Start pressure test.
Pressure test
Start pressure test
now
High
For-
After
7. In the pressure test window check that all the items listed have been completed.
Pressure test
Switch on communication.
Feed compressed air to the system.
Check SCF gas supply:
Gaseous N2 or CO2.
Open gas supply and feed gas into the system until a pressure of at least 14.5 bar
(210 psi) has been reached.
Close SCF drainage valve on the rear side of the device.
Start pressure test.
Everything understood
Cancel Help Execute
8. Tick off ’Everything understood’.

9. Press [Execute].
The test will start. The current reading ’now’ is displayed for the three positions ’high’
(pump pressure) ’before’ (pressure in front of measuring point) and ’after’ (pressure
after measuring point).
The starting value is ’0’ entered in the column.
The current value is recorded in the respective column every 15 minutes.
Pressure test
Start pressure test
now
High
For-
After
10. The test takes 60 minutes. To abort the test, deactivate the ’Start pressure test’ screen
switch.
11. If the pressure drop during the test is greater than 41 bar (600 psi), search for leaks and
eliminate them.
12. Repeat test.
181
Maintenance
5 Maintenance of the safety devices

Check all machine safety devices whenever you perform maintenance tasks.
For function description of safety equipment, see ’Operator Manual’.
5.1 EMERGENCY STOP buttons

When EMERGENCY STOP is actuated, all motors of the machine must be switched off.
The EMERGENCY STOP buttons are located on the control panel of the injection molding
machine and - depending on the machine type - in the following areas:
 on the rear side of the injection molding machine
 on the robot manual control unit
 at the safety gate of a safeguard
 inside a safeguard
! CAUTION!
Risk of injury from EMERGENCY STOP button with key!
Hand injuries may result during actuation when the key is in the EMERGENCY
STOP button.
Only insert the key into the EMERGENCY STOP button to unlock.
Information
For an overview of E-Stop buttons refer to the wiring diagram.
Check all E-Stop buttons in sequence as following.
Procedure:
1. Close all safety gates
2. Switch on the motors
3. Actuate EMERGENCY STOP pushbutton
 All movements and motors must stop immediately!
 The E-Stop alarm appears on the screen.
4. Unlock the EMERGENCY STOP button by turning it clockwise.
For the EMERGENCY STOP button with a key, unlock the button by turning the key
clockwise.
5. Activate the Program Interruption switch to acknowledge the alarm

Maintenance
5.2 Moving safety gates

Carry out the following tests for all moving safety gates and protection doors:
 Visual check for wear and damage.
 Check fastenings, guides (for smooth running), stops and locking mechanisms by open-
ing and closing the safety gate.
 Check the switching function of the safety and/or monitoring elements (e.g. limit
switches, valves, screen flags) by opening and closing the safety gate and/or protection
door.
 Check whether all dangerous movements stop by opening the safety gate and/or pro-
tection door.
NOTICE!
Danger of damage from injection mold!
Dismount the injection mold if needed.
Retract nozzle, heat material barrel to correct temperature, and purge.
Set low speed (10%) for movements before doing so.
Procedure:
2. Switch on motor
3. Actuate the applicable machine movement and open the safety gate during the move-
ment.
 It should not be possible to open the safety gate! (electrically locked)
Information
When opened, some safety gates trigger an EMERGENCY STOP. Check as per EMER-
GENCY STOP buttons.
183
Maintenance
A screen page displays the signals to check the switching functions of the safety gates.
screen page
Safety equipment
Components Tasks
System settings
Peripheral unit
Carry out the following tests for automatic safety gates:
 Visual check for contamination and damage.
 By opening the safety gate in manual mode check that all potentially dangerous move-
ments are stopped.
Procedure [See Moving safety gates on page 183.]
 Check correct functioning of the safety strip
Switching functions
Display of signals for checking the switching functions.
Example: Screen flags Clamping unit safety gate closed and closing movement hydrau-
lically enabled.
Safety equipment
Clamping unit safety gate 1
A31:DI1 1
closed 1
open 0
Hydraulic closing safety
A3361:DI0 2 =11-S25 3 =11-Y25 4

Valve open 1 0
Valve closed 0 1 =11-S27
Error
Electric safety gate
Safety gate activated in sequence
Opening stroke in semi-automatic mode 0 mm

Safety gate 1 brake opening A242:DO9
final position Braking limit switch Safety strip
closed A31:DI1 A192:DI14 A41:DI26
open A192:DI13
Direction Open Close
Clamping unit safety gate 2
A192:DI9 5
closed 1
open 0
1. Signal from the monitoring module for the safety gate 1.

2. Limit switch monitoring safety valve open (Signal 1).
3. Limit switch monitoring safety valve closed (Signal 0).

Maintenance
4. Safety valve actuation.

5. Signal from the monitoring module for the safety gate 2.
Safety edges are fitted to the safety gate to protect persons. When actuated the safety gate
movement stops and the following message is displayed:
Safety gate x safety strip actuated

Safety gate x safety strip opening actuated
Effect No automatic operations. clamping unit side and injection unit side
movements blocked, after a short stop period the safety gate slowly
moves in the opposite direction
Remedy Safety edge relief
Clamping unit safety gate x open-close
Effect Blocks all machine movements, motor start, and cycle start in manual
and semiautomatic modes.
Remedy Check for correct switching sequence by opening and closing the
safety gates.
185
Maintenance
Hydraulic closing safety

When a safety gate is opened, the hydraulic closing safety closes and interrupts the hydraulic
link to the clamping cylinder. Limit switches monitor the positions of the hydraulic closing
safety valves.
If the closing safety does not switch correctly, an error icon appears in the Errors line for the
respective flags and alarms:
Hydraulic closing safety defective
Cause The valve did not switch correctly within a second when the safety
gate was opened or closed.
Effect Alarm lamp, motor stop.
Remedy Check perfect switching sequence of limit switch and safety valve by
opening and closing the safety gate.
For large-scale machines with cartridge and pilot valve:
Hydraulic closing safety x cartridge defective
Cause The cartridge (globe valve) of the hydraulic closing safety has not
closed within one second during opening of the safety gate.
Remedy Check the cartridge of the hydraulic closing safety.

Check perfect switching sequence of limit switch and safety valve by
opening and closing the safety gate.
Reset by closing the mold, which forces the cartridge to open. To do
this, enable the motor start; mold closing moves at the set-up speed.
Example: Screen flags nozzle safety gate open

Safety equipment
Nozzle safety gate
closed
open
Error
The following alarm is displayed if the limit switches do not switch correctly:
Nozzle safety gate x defective
Cause The two safety gate signals are simultaneously ’’1’’ or simultaneously
’’0’’.
Remedy Check for perfect switching sequence of signals by opening and clos-
ing the nozzle safety gate.

Maintenance
5.3 Mounting aid

If the acknowledgement key or a contactor (in the case of contact multiplication) is defective,
it is not possible to restart.
screen page
safety gate
The screen page is typically under the following components and tasks:
Components Tasks
System settings
Peripheral unit
Mounting aid
Mounting aid 1
in operation position 1 0
not in operation position 0 1
Error
Acknowledgement mounting aid
Acknowledgement key
acknowledged 1 0 1
Not acknowledged 0 1
Nozzle 1
advanced 1 0
„not advanced 0 1
Error
Function
Pressing the acknowledgement key activates two contactors in parallel, and the positions of
the acknowledgement contactors are monitored by digital inputs in the software.
The ’nozzle in contact position’ limit switch is also monitored by two contactors activated in
parallel via digital inputs in the software.
Mounting aid defective
Cause Both digital inputs of the mounting aid have been activated/deacti-
vated simultaneously for more than 1 second.
Effect All injection unit and clamping unit side movements blocked, motor
stop.
Remedy Check correct switching response of safety limit switches by latching/

unlatching the mounting aid.
187
Maintenance
Mounting aid acknowledgement contactor defective
Cause Monitoring inputs of the acknowledgement contactors have been

active or inactive simultaneously for longer than one second.
The error state continues following control voltage switch-off until the
error is acknowledged.
Effect Motor stops, alarm message.
Remedy Check the acknowledgement contactors and their antivalent switch

positions.
Nozzle contact limit switch defective
Cause The nozzle limit switch front monitoring inputs have been active for
more than 1 second simultaneously, or have not been active.
The error state remains until the error is acknowledged by switching
off the control voltage.
Effect The pump motor stops immediately.

Alarm message.
Remedy Have an experienced service engineer check the contactors and their
antivalent switch positions

Maintenance
5.4 Maintenance safety gate

The maintenance safety gates are also secured with safety limit switches that are integrated
in the Emergency Stop circuit.
Example:
1
[1] Additional limit switch ’Maintenance safety gate 1 open’

[2] Maintenance safety gate 1 open
[3] Maintenance safety gate 2 closed
The function of the safety limit switch is monitored in the control unit in respect to the transpon-
der signal.
If a signal ’Maintenance safety gate x open’ becomes active, the signal ’Safety gate x closed’
must become inactive within a monitoring time.
Clamping unit maintenance safety gate x actuator defective
Cause When opening the maintenance safety gate, the safety gate closed
signal must change to 0 within 0.5 seconds.
Effect All machine movements blocked, alarm lamp, motor stop.
maintenance safety gate.
Information
You need to check the function of the maintenance safety gates by opening and closing them
for monitoring against defects or manipulation, at Maintenance interval 1 (1440 h)!
If you perform the test sequence shortly before Maintenance interval 1 (yellow range), the test
is deemed to be performed and the prompt for inspection does not appear until the next main-
tenance interval is reached.
Once Maintenance interval 1 is reached (>=100%) or reset without a test run, the prompt for
testing appears.
189
Maintenance
Clamping unit maintenance safety gate x open - close
Effect Blocks all machine movements in manual mode, no motor start and
cycle start possible.
maintenance safety gate.
a) Machine safety gate active (no fencing safety gate):
Open and close maintenance safety gate while the machine safety
gate is closed.
b) Fencing safety gate active:
Open and close maintenance safety gate together with machine
safety gate (linked , open).
a) The following switching process must be executed without fault for this:
WTx ... Maintenance safety gate x

SVDx ... safety gate x
SVDx
WTx
Example: Clamping unit on operator side of machine, view from above
1. Initial state: Signal ’Safety gate x closed’ active, Signal ’Maintenance safety gate x
open’ inactive.
2. Signal ’Safety gate x closed’ becomes inactive and, within a monitoring time, signal
’Maintenance safety gate x open’ active.
3. Signal ’Safety gate x closed’ becomes active and, within a monitoring time, signal
’Maintenance safety gate x open’ inactive.
b) The following switching process must be executed without fault for this:
(A limit switch ’Safety gate x fully open’ is installed here.)
WTx ... Maintenance safety gate x

SVDx ... safety gate x
SVDa SVDa ... Safety gate x fully open
SVDx RBx ... Locking bolt x, connects the safety gates
RBx
WTx
Example: Clamping unit on operator side of machine, view from above
1. Initial state: Signal ’Safety gate x fully open’ active, Signal ’Maintenance safety gate x
open’ inactive.
2. Signal ’Safety gate x fully open’ becomes inactive and, within a monitoring time, signal
’Maintenance safety gate x open’ active.
3. Signal ’Safety gate x fully open’ becomes active and, within a monitoring time, signal
’Maintenance safety gate x open’ inactive.

Maintenance
5.5 Safety limit switch for swiveling out injection unit

Swiveling out of the injection unit makes it easier to set up the barrel for injection. A limit switch
interlocks all injection unit movements while the injection unit is swiveled out.
Functional check:
Press limit switch to ensure that all hazardous movements are stopped.
NOTICE!
Danger of damage from injection mold!
Dismount the injection mold if needed.
Retract nozzle, heat material barrel to correct temperature, and purge.
Set low speed (10%) for movements before doing so.
Procedure:
2. Switch on motor
3. Injection unit in operating position (swiveled in).
4. During a function movement on the injection unit,
for example: Advance injection unit , manually actuate the safety limit switch.
The functional movement Advance injection unit must stop and an error message
appears.
Nozzle x swivelled out
Effect Cycle interruption.
Remedy Swivel in nozzle.
Information
For machines with pressure accumulator, the safety limit switch for swiveling out the injection
unit is in the EMERGENCY STOP system
Functional check for machines with pressure accumulator

2. Switch on the motors
3. Open nozzle safety gate (not for injection unit with open construction type)
4. Actuate limit switch manually.
 All motors must stop immediately!
 The alarm lamp must flash.
 An EMERGENCY STOP alarm message is displayed.
 All machine movements must be blocked!
5. Activate the Program Interruption switch to acknowledge the alarm
191
Maintenance
Information
The EMERGENCY STOP function is active in each mode of operation!

Maintenance
5.6 Fixed gate for delivery chute

The injection molding machine is delivered with the required safety gate for the delivery chute.
If you have dismount safety gates to support machine operations with peripheral equipment in
the delivery area (e.g. conveyor-belts, stacking devices etc.) make sure the safety measures
you take do not impact safety levels!
! WARNING!
Danger of crushing due to missing covers!
It must be impossible to reach into the clamping unit danger area.
If you then operate the machine without peripheral equipment, make sure you
restore the original the safety gates to their original state.
193
Maintenance
5.7 Contact multiplication safety gates

(optional)
For injection molding machines with extensive safety-relevant options (e. g. core, robots, ...),
additional monitoring contactors are required for some safety devices.
Possible safety equipment with monitoring contactors:

 Safety gate on the clamping unit
 Nozzle safety gate
 Mounting aid
Example: contactor monitoring safety gate

Contactor monitoring safety gate 1
A402:DI3 A702:DI3
closed 1 0
open 0 1
Error
Additional contactor safety gate x closed defective

Additional contactor safety gate x open defective
Additional contactor safety gate x open (closing safety) defective
Additional contactors safety strip x defective
Clamping unit safety gates sum contactors x defective
Additional contactor safety gate x acknowledged defective
Additional contactor safety gate x not acknowledged defective
Cause Two digital inputs, triggered by the additional contactors of the moving
safety gates, are simultaneously activated / deactivated for more than 1
second.
Effect Motor stop
Remedy Check for correct switching sequence of additional contactors by open-

ing/closing safety gates (also acknowledgements if existing).
Additional contactor Fencing safety gate x closed defective

Additional contactor Fencing safety gate x open defective
Additional contactor Fencing safety gate x open (closing safety)
defective
Cause Two digital inputs, triggered by the additional contactors of the safety
guarding, are simultaneously activated / deactivated for more than 1 sec-
ond.
Effect Motor stop
Remedy Check for correct switching sequence of additional contactors by opening/

closing safety gates (also acknowledgements if existing).

Maintenance
Additional contactor mounting aid x in operation position defec-

tive
Additional contactor mounting aid x not in operation position
defective
Additional contactor mounting aid x Assembly place acknowled-
ged defective
Additional contactor mounting aid x Assembly place not ack-
nowledged defective
Cause The monitoring inputs of the additional contactors were activated /

deactivated simultaneously for more than 1 second.
The error state remains until the error is acknowledged by switching
off the control voltage.
Effect Motor stops, alarm message
Remedy Correct switching process of additional contactors by moving the

mounting air in/not in operation position and acknowledgement.
Contactor monitoring nozzle x open defective

Contactor monitoring nozzle x closed defective
Additional contactor acknowledgement safety gate nozzle x ack-
nowledged defective
Additional contactor acknowledgement safety gate nozzle x not ack-
nowledged defective
Cause Two digital inputs, triggered by the additional contactors of the nozzle safety
guard, are simultaneously activated / deactivated for more than 1 second.
Effect Motor stop
Remedy Check perfect switching sequence of the additional contactors by safety

gate opening/closing.
195
Maintenance
6 Lubrication
Movable mechanical machine components require regular lubrication to reduce friction and
wear.
! WARNING!
Risk of injury from missing safety gates!
During maintenance work, the removal of a safety gate may be required.
After completing the maintenance work, properly mount the safety gate again!
NOTICE!
When lubricating through dirty or blocked grease nipples, no grease reaches
the lubrication point!
Clean the grease nipple prior to lubrication.
NOTICE!
Risk of damage to the guide carriage from an excessive exit velocity of grease
when using pneumatic grease guns.
Adjust air pressure to the flow behavior of the used grease prior to lubrication.

Maintenance
6.1 Lubrication Clamping unit
6.1.1 Lubricate pivot mount

(Maintenance interval 1)
Lubrication point
 Grease the lubrication point until grease starts to escape.

 Use grease as per lubricant overview.
[See Overview lubricants and hydraulic oils on page 210.]
197
Maintenance
6.1.2 Lubricate the high-speed clamping cylinder

Lubrication point


Maintenance
6.1.3 Lubricate guide carriage

Lubrication point
 Required amount of grease: approx. 15 cm³ (0.51 fl oz/US) per lubricating point and
greasing routine.
199
Maintenance
6.1.4 Lubricate guide carriage - safety gate

Lubrication point
 Required amount of grease: approx. 3 cm³ (0.10 fl oz/US) per lubricating point and
greasing routine.

Maintenance
6.1.5 Lubricate tiebar pulling device (optional)

Lubrication point

201
Maintenance
6.2 Lubrication Injection unit
6.2.1 Lubricate guide carriage

The guide carriages are located at operator side and non-operator side.
Example: Injection unit 860 - 2460
Guide carriage operator side

Lubricating nipple
 Wipe grease nipple clean with a cloth.

 Perform an initial lubrication using approx. 3 cm³ (0.10 fl oz/US) grease per lubrication
point.
 Move the guide carriage 2-3 times along its entire travel path.
 Perform a second lubrication using approx. 3 cm³ (0.10 fl oz/US) grease per lubrication
point.
 Use grease according to the lubrication table.

Maintenance
6.2.2 Lubricating the swiveling unit

There are 5 grease nipples on the swiveling unit.
Lubricating nipple
 Wipe grease nipple clean with a cloth.

 Perform lubrication using approx. 1 cm³ (0.03 fl oz/US) grease per lubrication point.
 Use grease according to the lubrication table.
203
Maintenance
6.2.3 Replace filter element

Air filters allow filtered air to provide equalization of the oil reservoir. Dirty air filters have a
major impact on the hydraulic system. Regular replacement ensures trouble-free operation.
Air filter
Filter element
 Replace filter element

 Dispose of the wetted filter element in accordance with the relevant regulations.

Maintenance
6.2.4 Change oil of the plasticizing drive

ENGEL recommends to have the used oil analyzed by the gear box oil supplier at mainte-
nance interval 4. If required, replace gear box oil.
 Change oil only when warm as the high viscosity of cold oil hampers proper draining.
 Pay attention to the technical data on the assembly drawing of the injection unit.
 Use a gear box oil as per the lubricant overview.
1. Switch off at main switch and secure against re-enabling.

2. Unscrew the Allen screws and remove the cover.
Cover
3. Unscrew the filler cap.

Filler cap
4. Place an oil tray underneath the drain cap.

5. Unscrew drain cap and collect oil in oil tray.
Drain cap
6. Screw in the drain cap.
205
Maintenance
7. Fill to the middle of the oil level indicator tube ± 10 mm (± 0.39 in). It takes approx. 5 min-
utes for the oil level to equalize with the sump level.
Oil level indicator tube

8. Screw in the filler cap.
9. Assemble cover.

Maintenance
6.2.5 Change oil of screw bearing

We recommend you have the used oil tested by the gearbox oil supplier and change this as
per supplier's recommendation.
NOTICE!
Carry out the first oil change after 1000 hours of operation.
Filler cap
Sight glass
Drain cap
 For required amount of oil refer to type plate at the plasticizing gear unit.
 Fill to the middle of the inspection glass (± 10 mm, ± 0.39 in).
It takes approx. 5 minutes for the oil level to equalize with the sump level.
 Pay attention to the technical data on the assembly drawing of the injection unit and
gears.
207
Maintenance
6.2.6 Oil change at the screw drive

We recommend you have the used oil tested by the gearbox oil supplier at maintenance inter-
val 4 and change this as per supplier's recommendation.
Filler cap
Sight glass
Drain cap
 The oil filling level is approx. 7 liters (1.85 gal/US).

 Fill to the middle of the inspection glass ± 10 mm (± 0.39 in).

Maintenance
6.2.7 Gear assembly oil change

We recommend having the used oil tested in maintenance interval 4 by the gear oil supplier
and follow their recommendations for oil changes.
NOTICE!
Carry out the first oil change after 100 hours of operation.
Filler cap
Sight glass
Drain cap
 Amount of oil required for initial filling: approx. 2,2 liters (0.58 gal/US).
 Fill to up to ± 10 mm (± 0.39 in) on the middle of the sight glass on the oil level indicator.
209
Maintenance
6.3 Overview lubricants and hydraulic oils

You can find an overview of all lubricants and hydraulic oils approved by ENGEL here.
6.3.1 Lubricant
Grease lubrication Transmission lubri- Oil for

manual cant Central lubrication
norm DIN 51825 KP2K-20 DIN 51517 T3 DIN 51502 CGLP

Lithium saponified CLP VG 320
SIGNUM EPX 2 STEELO SLIDO 68

HST320
SIGNUM EPX 2 GEAR HST 320 GLIDE 68
Oils and lubricants by Lukoil and OMV are identical products.
ARALUB HLP 2 DEGOL 320 DEGANIT

B 68
RENOLIT FEP2 RENOLIN CLP 320 RENEP

CGLP 68
GR MU EP 2 BLASIA 320 EXIDIA HG68
ENERGREASE LS EP 2 ENERGOL GR-XP 320 MACCURAT

D 68
SPHEEROL EPL 2 ALPHA SP 320 MAGNA BD 68
BEACON EP 2 SPARTAN EP 320 FEBIS K 68
MOBILUX EP 2 MOBILGEAR 600XP VACTRA Nr.2

320

Maintenance
Grease lubrication Transmission lubri- Oil for

ALVANIA EP2 OMALA 320 TONNA T 68
GADUS S2 V220 2 OMALA S2G 320 TONNA S2 M 68
MULTI DUTY SUNEP 320 WAY LUBRICANT 68

GREASE EP2
MULTIFAK EP 2 MEROPA 320 WAY LUBRICANT X68
MULTIS EP 2 CARTER EP 320 DROSERA

MS 68
KLÜBERPLEX KLÜBEROIL LAMORA D-68

BEM 41-132 GEM 1-320N
Information
In order to keep the steel strip guides free of water, we recommend the use of oil (ENGEL
Order No. 04201-0017) for central lubrication [See Cleaning of machine on page 164.]
Information
A lubricant safety fact sheet is available from the manufacturing works on demand.
211
Maintenance
6.3.2 Hydraulic oils
Hydraulic oils zinc-based Hydraulic oils - zinc-free
norm DIN 51524-2 DIN 51524-2

ISO VG46 ISO VG46
GEYSER ST 46 GEYSER ZF 46
GEYSER S 46
HYD HLP 46 HYD HLP AL 46
HYD HLP-SHS 46
Oils and lubricants by Lukoil and OMV are identical products.
SINOPEC AE 46 SINOPEC L-HM 46
VITAM GX 46 VITAM GF 46
RENOLIN B15 RENOLIN ZAF D46 HT

RENOLIN MR 46 MC RENOLIN ZAF B46 HT
RENOLIN XTREM TEMP 46 PLUS RENOLIN ZAF 46 MC
OSO 46
ENERGOL HLP HM 46
HYSPIN AWS 46 HYSPIN ZZ 46
NUTO H 46

Maintenance
Hydraulic oils zinc-based Hydraulic oils - zinc-free
DTE 25 DTE EXCEL 46
TELLUS S2 MX 46 TELLUS S3 M 46
TELLUS S2 M 46
SUNVIS 846 WR
RANDO
OIL HD C 46
AZOLLA ZS46 AZOLLA AF 46
Information
213
Maintenance
6.3.3 Food-safe lubricants and hydraulic oils (NSF-H1)
Grease lubrication Transmission lubri- Adhesive oil for

norm CLP 320 CLP 68
Rivolta Rivolta Rivolta

F.L.G GT-3 F.L. 400 F.L. 100
KLÜBERFOOD KLÜBEROIL KLÜBEROIL

NH1 94-301 4 UH1 - 320N 4 UH1 - 68N
CASSIDA CASSIDA CASSIDA

GREASE GTX2 FLUID GL 320 FLUID HF68
Hydraulic oil
norm DIN 51 502
OKS 3770
CASSIDA FLUID HFS 46
RIVOLTA F.L. 75
Information

Maintenance
7 Hydraulics
Overview of the hydraulic components
5 4
[1] Hydraulic oil reservoir with filling hole

[2] Low-pressure filter with soiling indicator (red button)
[3] Pump for oil filtration
[4] Oil cooler
[5] Sight glass
215
Maintenance
7.1 Change hydraulic oil

Under normal circumstances, a hydraulic oil change must be made at maintenance interval 4.
Circumstances may dictate an oil change earlier, however.
We recommend having the oil condition checked at six month intervals by your hydraulic oil
vendor, and changing the hydraulic oil based on your vendor's recommendations!
NOTICE!
Danger to environment, danger of fire!
When draining and disposing of use oil, avoid pollution and avoid endangering
your environment. Follow local waste-disposal laws when draining and dispos-
ing of oil.
Change process:
1. Dismount the filling and venting filter
2. Use a suction pump to draw off the used oil, and drain the remaining oil via the oil drain
screw (at the bottom of the oil tank) into catchment trays
3. Dismount cleaning cover on the oil tank
4. Clean sludge from the oil tank wall and floor
5. The used oil must be disposed of legally, in line with waste-disposal laws
6. Screw in oil drain plug
7. Mount cleaning cover on the oil tank
8. Mount the filling and venting filter
9. Top up with hydraulic oil

Maintenance
7.1.1 Fill hydraulic oil

The machine is supplied as standard with an empty oil tank and may only be put into operation
after it has been topped up with hydraulic oil.
NOTICE!
Information
Use only hydraulic oils of the specified viscosity "ISO VG46". A safety data sheet for hydraulic
oils is available from the manufacturer on request.
If the event of a change of brand of hydraulic oil, the entire hydraulic oil content must be
replaced. If you need to top up with a hydraulic oil other than the one employed, contact the
oil vendor to ensure miscibility.
The oil fill volume is specified on the machine and in the documentation on the foundation plan.
NOTICE!
Danger of equipment damage to clamping unit from residual oil!
In closed state the clamping unit contains residual oil. When the volume of oil
as per type plate is filled, too much oil will be inside the hydraulic system. Sub-
sequent mold opening will cause significant equipment damage to hydraulic
oil components.
If the clamping unit is closed, fill only to the minimum mark in the sight glass.
Procedure for hydraulic oil filling:

1. Open the filler cap on the oil tank.
2. Only use a filling device fitted with a depth/fine filter with a filter mesh of < 10 µm- that
complies with ISO 16889 to fill the oil tank:
 Use only HLP46 hydraulic oils that meet standard DIN 51524-2 to fill the oil tank.
 Permissible degree of soiling/purity as per ISO 4406:1999 <=17/15/11.
 The oil fill level must be in the top third of the sight glass while the clamping unit is
open, but in the bottom third when the clamping unit is closed!
3. Close oil tank filling aperture with filler cap.
4. Vent hydraulic system.
217
Maintenance
7.1.2 Vent the pump

A small delivery rate and speed is prescribed for a gentle start of the hydraulic fixed displace-
ment pump.
The ’vent the pump’ program is activated either automatically via the control unit or manually
by the service technician. Owing to the reasons covered by guarantee, pump venting is logged
in the control unit.
 Automatic activation:
 When commissioning
 When the oil level switch responds
 Manual activation:
 When commissioning at the customer's location
 After changing a pump
 After an oil change
NOTICE!
Use of an unvented pump will damage the pump system.
Vent the pump as per the instructions when commissioning it.
Venting procedure:
1. Install a suitable hose with leakage oil reservoir on the miniature measuring point on or
in the proximity of the pump according to the hydraulics schematic.
[1] Fixed displacement pump
[2] miniature measuring point
2 [3] Leakage oil reservoir
2. Wait until there is some oil in the oil leakage container.

This may take up to 30 minutes depending on the design.

Maintenance
3. Also loosen the bleeder screw on Voith pumps until oil discharges. Air is thereby able to
escape more quickly. Then re-tighten.

5. Set the ’Pump venting mode’ variable to ’Yes’ in the ’Pump x’ list of variables.
 Display of the ’pump venting mode =>set-up mode’
6. Select the pump to be vented with the ’Start venting outputs for pump no. (0=off)’ vari-
able.
NOTICE!
Risk of damage! Ensure that there is some oil in the oil leakage container before
motor start. This means that there is oil in the pump space, and the pump is not
dry when running.
7. Start the venting with the Motor ON/OFF switch.

CAUTION!
Hydraulic oil may discharge abruptly from the venting line! Arrange for suit-
able safety measures.
 Display of the ’venting of pump x active’

8. Vent until oil discharges without bubbles at the measuring hose.
9. End the venting with the ’Start venting outputs for pump no. (0=off)’ variable or with
motor ON/OFF key.
10. Remove the miniature measuring hose.
Effects when ’vent the pump’ active:
Alarms
Pump venting mode => set-up mode

Pump venting mode (oil level) => set-up mode
Cause Activation of the ’vent the pump’program.
Effect Motor start possible only in the set-up mode
Remedy Automatically after switching off pump venting
Venting Pumpx active
Cause Pump venting was started
Remedy After oil discharges without bubbles, switch off pump venting
219
Maintenance
Parameters in the variables monitor
typ. value
Variables group: Pump 1 Long text Level
Unit,
Pump1.sv_bPumpVentilationMode Pump venting mode 11
Pump1.sv_iVentilationPumpUnitId Start venting releases for pump no. (0=off) 11
Pump1.sv_rPumpVentilationV Volume venting the pump 12
Pump1.sv_rPumpVentilationP Vent pump pressure 12

Maintenance
7.1.3 Vent hydraulic system
Information
After filling/changing hydraulic oil, and after working on the hydraulics system, you must vent
the hydraulic cylinder.
How to detect air in the hydraulic system:

 Bubbling
 Jerky functional movements of clamping and injection unit
 Abnormal noises
Venting procedure:
1. Set maximum stroke and low values for pressure and speed (ca 20%) for functional
movements.
2. Run the machine through a complete stroke in set-up mode - 8 to 10 times in each case:
 Ejector - advance/retract
 Nozzle - forward/return
 Injection/Screw retraction
3. After completing the venting process, check the hydraulic oil level and top up with
hydraulic oil if needed!
Oil level too low
Cause Hydraulic oil level too low.
Effect Motor stops, heating systems ramp down, alarm lamp flashes.
Remedy Fill up with hydraulic oil, and repair any leakages.
221
Maintenance
7.1.4 Change the hydraulic oil from zinc-containing to zinc-free

When switching to a different hydraulic oil, an intermediate flush is required. Suitable hydraulic
oils [See Hydraulic oils on page 212.]
NOTICE!
Example: Changing to non zinc-based hydraulic oil

1. Drain used oil.
 See the description in ’Hydraulic Oil Change’.
Some 10 - 15% of residual used oil will remain in the machine!
2. Fill with non-zinc hydraulic oil.
 See the description in ’Filling in Hydraulic Oil’.
3. Perform all machine movements at full stroke in dry cycle (for approx. 15 minutes).
 Ejector - retract/advance
 Nozzle - contact/retraction
 Injection / plasticizing
 This mixes the used and new oil.

4. Repeat oil change.
 Drain used oil.
 Fill with non-zinc hydraulic oil.
If the injection molding machine is delivered with non zinc-based hydraulic oil, the following
pictogram is shown on the hydraulic oil reservoir. Remove the pictogram when changing to
zinc-based hydraulic oil.
Pictogram
Filling with zinc-based hydraulic oil not permitted!

Standard mounting adjacent to hydraulic oil reservoir.

Maintenance
7.2 Hydraulic system
7.2.1 Pump
If a pump malfunction occurs, contact your local service engineer.
Some machines have tank shut-off valves to help remove the defective pump. If the tank shut-
off valve is not completely open, the following message appears:
Tank shut off valves closed
Cause Shut-off valve in the pump suction line is not open. Digital input F1
not set + 24VE.
Effect Motor shuts down, heaters reduce to stand-by, alarm message,
Remedy Open the shut-off valve Check the limit switch.
223
Maintenance
7.2.2 Hydraulic lines

Hydraulic lines are subject to natural aging and the period of use is therefore limited.
1 2 3
[1] Fitting
[2] Insert
[3] Outer layer

Maintenance
! WARNING!
Risk of injury from damaged or old hydraulic lines!
Damaged hydraulic lines or hydraulic lines whose useful life has expired may
burst during operation and cause serious injury.
Check that all hydraulic lines on the hydraulic unit are in a safe working condi-
tion at maintenance interval 2.
Replace the hydraulic lines after 6 years from the date of manufacture.
This test must be performed by a recognized expert.
A qualified person is a person who has sufficient knowledge in the field of hydraulic lines due
to his professional training and experience.
The expert must be familiar with the relevant health and safety regulations, accident preven-
tion rules, technology guidelines and best practices, to an extent that the expert can judge
whether hydraulic hoses are in a safe state for use.
Possible faults:
The following examples show the main defects that require urgent replacement of the hydrau-
lic lines.
 The outer layer of the hydraulic line is damaged up to the insert (chafing, cuts or cracks).
 The outer layer is brittle (cracks in hose material).
 The hydraulic line is deformed or becomes deformed in the pressureless or pressurized
state or when bent, for example delamination, blistering, crushing or kinking points.
 The hydraulic line is leaking.
 The hydraulic line exits the fitting.
 The fitting is damaged or deformed (strength of fitting or connection hose/fitting
impacted).
 The fitting is corroded - impact on functionality and strength.
 The product lifetime has expired (see manufacturing date on hose fitting).
How to replace the hydraulic lines.

When replacing the hydraulic lines, please note the following:
 Only use original spare parts.
Make sure that the hydraulic lines have the correct capacity and that the lengths or fit-
tings match.
 Keep to the original installation position, do not modify hose clamps or the bend radius.
 Tighten the hydraulic lines to the specified torque (see table).
Information
The tightening torques are only for ’’DKO nuts’’ and nuts of HD screw connections.
225
Maintenance
Nut of HD hose Thread SW build-up tightening

’’Heavy’’ material torque
Nut of HD screw connec-
tion
’’Heavy’’
D=06 NW03_L4 M14x1.5 SW19 GE 06-SW 35Nm

(25.8 ft.lbf)
D=08 NW04_L4 M16x1.5 SW19 GE 08-SW 40Nm

(29.5 ft.lbf)
D=10 NW06_L4 M18x1.5 SW22 GE 10-SW 50Nm

(36.8 ft.lbf)
D=12 NW08_L4 M20x1.5 SW24 GE 12-SW 60Nm

(44.2 ft.lbf)
D=14 NW10_L4 M22x1.5 SW27 GE 14-SW 75Nm

(55.3 ft.lbf)
D=16 NW12_L4 M24x1.5 SW30 GE 16-SW 80Nm

(59.0 ft.lbf)
D=20 NW16_L4 M30x2 SW36 GE 20-SW 120Nm

(88.5 ft.lbf)
D=25 NW20_L4 M36x2 SW41 GE 25-SW 170Nm

Nut of HD screw connection SW46 (125.4 ft.lbf)
D=30 NW25_L4 M42x2 SW50 GE 30-SW 250Nm

(184.4 ft.lbf)
D=38 NW32_L4 M52x2 SW60 GE 38-SW 350Nm

(258.1 ft.lbf)
Safety instructions:
Hydraulic lines must not come into contact with substances that can cause damage such as
acids, alkalis, solvents.
Do not use ozone-emitting lighting fixtures or devices that generate sparks in the immediate
vicinity.
Avoid reusing hydraulic lines.
The first use of the hose can impact the hose material's characteristics so that reuse becomes
dangerous.

Maintenance
7.2.3 Hose safety catch

Tubing of hydraulic barrel shut-off nozzles and ejector couplings with DN4 measuring hoses
must be secured with hose safety catches at both ends.
! WARNING!
Danger from high pressure DN4 measuring hoses!
Secure DN4 measuring hoses with hose safety catches!
Method of operation:
Safety stop cable
Hose safety catch
Hose line
Fitting
If the connection between the hose line and the fittings becomes loose under pressure, the
arrester cable contracts and prevents the hose from flying off.
227
Maintenance
7.2.4 Manometer
Depending on the machine type, manometers for checking hydraulic pressure may be fitted at
various positions (e.g. for cores).
Manometer
Shut-off valve
Open the manometer shut-off valve only for the pressure test!
Then close the shut-off valve to prevent damage to the manometer!

Maintenance
7.3 Oil temperature control

The optimum hydraulic oil temperature is 35 °C (95 °F).
screen page
Oil temperature control
Components Tasks
Production relevant screens
Peripheral unit
Example: oil temperature control

Zones
Maximum temperature °C
Cooling from °C
Oil preheating to °C
Minimum temperature °C
If the oil temperature is below or drops below the configurable minimum temperature while the
motors are running in manual mode, a hydraulic oil preheating program automatically starts
with the following message
Oil temperature too low for automatic mode
Cause Oil temperature below minimum temperature (or below target value
after control unit is switched on).
Effect Automatic mode locked until minimum temperature reached.
Movements in manual and set-up mode are possible. Here the oil preheating program stops
and starts anew after finishing the movement. The switchover to automatic mode is blocked,
however! The release occurs with exceeding the minimum temperature.
The settings for oil preheating are:
229
Maintenance
screen page
Pump overview
Components Tasks
System
does not exist
Example: Pressure and volume control for a oil preheating pump

Overview
Oil heating
Supply for maximum amount of oil 181,0 l/min
Oil preheating pressure 140,0 bar
Information
During oil preheating, the motor runs at maximum speed, in order to avoid overloading the
motor through continuous exceeding of the nominal torque.
Alarms
Oil temperature too high
Cause The hydraulic oil has exceeded the set maximum temperature.
Effect Alarm lamp, production stop.

If the temperature rises above 60 °C (140 °F), the motor will switch
off.
Remedy Open cooling water, check cooling water supply and temperature,
clean oil cooler.
No oil temperature change
Cause Temperature must rise by at least 2 °C (3.6 °F) within 5 minutes

during oil preheating.
Possible problem with thermocouple or hydraulic system
Effect Motor stops
If the oil flow through a pump with servodrive is too low for an extended period (5 min) at the
corresponding pressure, the following message will be displayed:

Maintenance
Impermissible heating pump x
Cause Long post-injection times, slow plasticizing, final position of a move-

ment not reached
Effect Motor stop, alarm lamp
Remedy Check settings
No oil temperature change
Cause Temperature must rise by at least 2 °C (3.6 °F) within 5 minutes

during oil preheating.
Possible problem with thermocouple or hydraulic system
Effect Motor stops
231
Maintenance
7.3.1 Oil cooler

The oil cooler for the hydraulics is fitted in the main tank line or in a separate cooling and filter-
ing circuit depending on the machine type. Depending on the level of contamination and lime
content of the water, the cooling system requires regular cleaning.
Excessive oil temperature during machine operations is indicative of reduced cooling perfor-
mance.
Another way of detecting contamination is to measure the oil cooler flow rate.
Oil cooler type PWO
1
4
3
2
[1] Water feed

[2] Hydraulic oil
[3] Water return
[4] Electric solenoid valve
Cleaning options:
 Flushing with water removes contamination
 Allow a slightly acid solution to circulate several times against the normal water flow
direction
Use 5% phosphoric acid solution, or 5% oxalic acid solution for frequent cleaning.
After acid treatment rinse heat exchanger thoroughly with water.

Maintenance
7.4 Oil filter

The low pressure filter is part of a separate auxiliary circuit, or fitted immediately upstream of
the oil tank, and equipped with a mechanical/electric contamination warning mechanism.
You need to replace the filter element when:

 the red button pops out
 a message appears on screen
 hydraulic oil has been changed
During cold starts the red button on the indicator may pop out.
Do not push the red button back in until operating temperature has been reached.
If it immediately pops out again (indicating excessive differential pressure), make sure you
replace the filter element.
Message:
Check oil filter, check high pressure filter, check return filter, no
oil filtration,
Cause +24V not applied to digital input F2, oil filter contaminated, motor for
auxiliary flow filtration switched off.
Effect Machine stops active cycle, alarm lamp flashes. Motor ramps off,
heating ramps down.
Remedy Check oil filter and filter motor.
Information
If filter elements are only replaced infrequently or not at all and the contamination indicator
does not show any need for replacement, this can have several causes.
Dirt particle penetration, a defective filter element or a defective contamination indicator.
The oil filter and contamination indicator therefore have to be checked for correct functioning
every six months.
233
Maintenance
7.5 Auxiliary flow filtration

In this case, filtration and cooling of the hydraulic oil do not occur on the main line, but in a sep-
arate cooling circuit with a separate pump.
Filtration is always active while the pump motor is running, but can also be started separately
to filter fresh oil.
screen page
Pump overview
Components Tasks
System
does not exist
Example: Pressure and volume control for a oil preheating pump

Overview
Oil filtration
Oil filtration only
Filter motor 1 is running
Oil filtration only:

You can switch the program on manually; it switches on automatically when the oil level is too
low. Message:
Oil filtration active
Effect Main motor will not start, oil filtration active.
Remedy You may need to top up with oil, filter oil for sufficiently long period,
switch off oil filtration.
Filtering fresh oil:

1. Select ’Hydraulics overview’ screen.
2. Activate ’Only oil filtration’ program.
3. Switch on motors (only filter motor starts).
4. Run filtration for at least 3 hours.
5. Switch off the ’Oil filtration only’ program. Filter motor stops.
6. Acknowledge with ’Program interruption switch’.
7. The next time you switch the motor on, all motors will start again.

Maintenance
7.6 Bladder accumulator

Bladder accumulators on the injection molding machine hydraulics help individual functional
units to achieve higher speeds, or support parallel movements.
7.6.1 Check and fill the bladder accumulator
! WARNING!
Danger of fatal injury due to explosion!
Never fill with oxygen or air.
Use only nitrogen to fill the accumulator bladder.
Before checking, and before topping up with nitrogen, close the shut-off valve
to separate the bladder from the hydraulics system and to relieve.
Keep to the following steps for checking and filling using the filling and testing device, FTU-1:
Testing
1. Relieve pressure on bladder accumulator hydraulics side.

2. Remove protective cover and seal from bladder accumulator.
Spindle
Protective cap Relief valve
Sealing cap
Non-return valve
O-ring Manometer
Bladder accumu-
lator
Adapter A3
Filling
d
3. On the FTU-1 completely unscrew the spindle anti-clockwise.
4. Screw the FTU-1 onto the bladder accumulator, tighten by hand (use the supplied A3
adapter for bladder accumulator only). Make sure the o-ring is in place and not dam-
aged.
5. Close the relief valve on the FTU-1 tight.
6. On the FTU-1 turn the spindle clockwise to open the gas valve on the machine's bladder
accumulator. When the needle on the manometer starts to move, turn the spindle
through 360 degrees.
 The manometer will now show the accumulator's gas pressure.
 If the pressure is too low, or the pressure vessel is empty, top up with nitrogen. Gas
fill pressure in bladder accumulator - refer to hydraulics schematic.
7. If the pressure is too high, you can let off some nitrogen via the relief valve.
Careful opening of the relieve valve until the nominal pressure is reached.
235
Maintenance
8. Once the gas fill pressure is reached, turn the spindle on the FTU-1 anti-clockwise to
close the gas valve on the accumulator.
9. Use the relief valve to release the pressure on the FTU-1 and unscrew to remove. Make
sure the o-ring is in place and not damaged.
10. Use leak detector spray to check that the gas valve is tight.
11. Screw seal and protective cover back into place, observing tightening torque.
Nitrogen Filling
If the bladder accumulator is empty or below the nominal pressure (refer to hydraulic sche-
matic) nitrogen has to be topped up.
1. Perform items 1 through 6 of the previously described check.
2. If the gas pressure in the nitrogen cylinder used for filling is higher than the maximum
permitted operating pressure of the bladder accumulator, you must use a gas safety
valve or a pressure reduction valve!
If needed, use adapter G.
3. Connect the flexible filling hose to the pressure reduction valve on the nitrogen cylinder,
and to the filling and testing device on the bladder accumulator.
Pressure reduction valve
Filling hose
Filling and testing unit FTU-1
Adapter G
Nitrogen cylinder Bladder accumulator on

machine
4. Close the pressure reduction valve.

5. Carefully open the shut-off valve on the nitrogen cylinder, and slowly set the gas filling
pressure at the pressure reduction valve to avoid damage to the gas valve on the blad-
der accumulator.
6. Interrupt filling periodically to check the current filling pressure on the manometer.
7. Repeat this procedure until you have reached the required gas filling pressure.
8. After allowing the temperature to adjust to match the ambient temperature, check the
filling pressure again, and correct if needed.
9. Close the shut-off valve on the nitrogen cylinder, and remove the filling hose.
Careful opening of the relieve valve until the nominal pressure is reached.
11. Once the nominal pressure is reached, turn the spindle on the FTU-1 anti-clockwise to
close the gas valve on the accumulator.
14. Screw seal and protective cover back into place, observing tightening torque.

Maintenance
For more information, see the Bladder accumulator manual on the CD.
Before starting up the injection molding machine, you must have the pressure accumulator
and safety valve approved on site by your local authorities.
Present the following certificates to the authorities!

The test certificate for the pressure accumulator is in chapter: Plans and Protocols [See Pres-
sure accumulator test certificate on page 283.]
NOTICE!
The owner must organize regular reinspections.
Refer to your national authority for information regarding the type of and inter-
vals between tests.
7.6.2 Check and fill the diaphragm accumulator
! WARNING!
Danger of fatal injury due to explosion!
Never fill with oxygen or air!
Use only nitrogen to fill the membrane accumulator.
Before checking, and before topping up with nitrogen, close the shut-off valve
to separate the membrane accumulator from the hydraulics system and to
relieve pressure.
Keep to the following steps for checking and filling using the filling and testing device, FTU-1:
Testing
1. Relieving the pressure on the membrane accumulator hydraulics side.

2. Remove the protective cap from the membrane accumulator.
3. Use an Allen key (size 6) to loosen the Allen screw slightly by turning anti-clockwise
through approx. (1/2 turn).
Spindle
Protective cap
Relief valve
O-ring
Allen key
Non-return valve
Allen screw
Manometer
Filling
Membrane accumu-
lator with valve
237
Maintenance
4. Attach FTU 1 to the membrane accumulator (hand-tighten).

5. Close the relief valve on the FTU-1 tight.
6. On the FTU-1 turn the spindle clockwise to open the gas valve on the machine's mem-
brane accumulator.
 The manometer will now show the accumulator's gas pressure.
 If the pressure is too low, or the pressure vessel is empty, top up with nitrogen. Gas
fill pressure in bladder accumulator - refer to hydraulics schematic.
Carefully open the relief valve until the pressure drops to 40 bar (580 psi).
8. If the pressure is 40 bar (580 psi), turn the spindle on the FTU-1 anti-clockwise to close
the gas valve on the accumulator.
11. Fit the protective cap, observing tightening torque.
Nitrogen Filling
1. Perform items 1 through 6 of the previously described check.

2. If the gas pressure in the nitrogen cylinder used for filling is higher than the maximum
permitted operating pressure of the membrane accumulator, you must use a gas safety
valve or a pressure reduction valve!
3. Connect the flexible filling hose to the pressure reduction valve on the nitrogen cylinder,
and to the filling and testing device on the bladder accumulator.
4. Use the coupling nut to connect the flexible filling hose to the pressure reduction valve
(if used) on the nitrogen cylinder. (You may need to use a G adapter for the nitrogen cyl-
inder.)
Pressure reduction valve
Filling hose
Filling and testing unit FTU-1
Adapter G
Nitrogen cylinder Membrane accumulator

on machine
5. Close the pressure reduction valve.

6. Carefully open the shut-off valve on the nitrogen cylinder, and slowly set the gas filling
pressure at the pressure reduction valve to avoid damage to the gas valve on the blad-
der accumulator.
7. Interrupt filling periodically to check the current filling pressure on the manometer.
8. Repeat this procedure until you have reached the required gas filling pressure.
9. After allowing the temperature to adjust to match the ambient temperature, check the
filling pressure again, and correct if needed.
10. Close the shut-off valve on the nitrogen cylinder, and remove the filling hose.

Maintenance
Carefully open the relief valve until the pressure drops to 40 bar (580 psi).
12. If the pressure is 40 bar (580 psi), turn the spindle on the FTU-1 anti-clockwise to close
the Allen screw.
13. Use the relief valve to release the pressure on the FTU-1 and unscrew to remove.
14. Use an Allen key (size 6) to tighten the Allen screw to a torque of 20 Nm (14.8 lbf.ft).
Make sure the o-ring is in place and not damaged.
16. Fit the protective cap, observing tightening torque.
For more information, see the Bladder accumulator manual on the CD.
Before starting up the injection molding machine, you must have the pressure accumulator
and safety valve approved on site by your local authorities.
Present the following certificates to the authorities!

The test certificate for the pressure accumulator is in chapter: Plans and Protocols [See Pres-
sure accumulator test certificate on page 283.]
NOTICE!
The owner must organize regular reinspections.
Refer to your national authority for information regarding the type of and inter-
vals between tests.
239
Maintenance
8 Pneumatic
8.1 Maintenance unit

The compressed air line must be of the same dimensions as the maintenance unit it services.
The fitting direction is indicated by an arrow (direction of flow).
! WARNING!
Danger due to accidental functional movements!
Before commencing maintenance and repair work, close the shut-off valve on
the air maintenance unit.
The air maintenance unit was factory set to ensure perfect working of the
pneumatic equipment and must not be modified.
[1] Handwheel operating pressure

[2] Manual shut-off valve
[3] Manometer
[4] Filter tray
[5] Display for the condensate level
(Maximum fill height)
[6] Condensate drain (orange button)
Draining condensate:
Once a condensate level of approx. 10 mm (0.4 in) below the filter element has been reached,
you must drain the condensate manually.
1. Use a suitable catchment tray.
2. Drain condensate by pressing orange button.
3. Dispose of condensate legally, in line with waste-disposal laws.

Maintenance
Change filter element:

Change filter elements every 2 years or when pressure drop reaches 1 bar (14.5 psi).
1. Close manual shut-off valve.
2. Venting the system and devices.
3. Pull filter tray lock downwards and rotate to marking on filter tray.
4. Now unscrew and remove the filter tray anti-clockwise.
5. Replace the filter element by a new one.
6. Mount the components in reverse order (hold the new filter element at the bottom end
only).
Compressed air monitoring

The operating pressure is monitored by a pressure switch, (like the switch for step safety on
DUO machines, etc.).
This sensor is built in between the maintenance unit and the compressed air line.
Connection cable
Adjusting screw
Pressure scale
The switching point for the pressure switch is set with the adjustment screw and is set to moni-
tor the operating pressure.
Message when the operating pressure is not reached:
Compressed air monitoring machine circuit x
Cause There is either no or not enough compressed air being supplied to the
circuit.
Remedy Make the compressed air supply to circuit x available, check air main-
tenance unit and pressure switch
241
Maintenance
8.2 Hoses for the pneumatic system
! WARNING!
Danger of injury due to damage high-pressure lines!
All media lines on the injection molding machine must be checked at least
quarterly to ensure they are safe for use.
This test must be performed by a recognized expert.
An expert is a person who has sufficient knowledge in the field of the pneumatics due to their
technical training and experience.
The expert must be familiar with the relevant health and safety regulations, accident preven-
tion rules, technology guidelines and best practices, to an extent that the expert can judge
whether the compressed air lines are in a safe state for use.
Possible faults:
The following examples demonstrate the most important faults which require an urgent
replacement of the compressed air line.
 The compressed air line is damaged (wear and tear).
 The compressed air line is deformed, or deforms in pressureless or pressurized state,
and/or in case of bending, e.g. bubble formation, crushing or kinks.
 The compressed air line is leaky.
Replacing compressed air lines.
When replacing compressed air lines, the following must be observed:

 Only use original spare parts.
This helps to ensure that compressed air lines are sufficiently robust.
 Keep to the original installation position, do not modify compressed air lines or the bend
radius.
Safety instructions:
Make sure that compressed air lines do not contact substances that can cause damage, e.g.
acids, lyes, solvents.
Do not use ozone-emitting lighting fixtures or devices that generate sparks in the immediate
vicinity.
Avoid reuse of compressed air lines.
The first use of the compressed air line can impact the line material's characteristics so that
reuse becomes dangerous.

Maintenance
9 Service Request 24
(optional)
An extension to the service box and e-service.24 interface allows you to trigger a service
request as well on the control unit.
screen page
Service-request
The screen page is typically under the following components and tasks:
Components Tasks
Search cause of the fault
System settings
does not exist
Switch on the screen page using the Activate service request variable in the 'Service Request'
list of variables in the variables monitor. The screen page is available once the control unit has
been switched off/on.
Current group Service-request Show variables text Displays raw
Information
For more information on the remote service package and e-service.24 in general, go to
www.engelglobal.com
Alarm selection
Alarm class 1 Alarm class 2

 Alarm selection
Selection option for 6 alarm classes that can trigger an automatic service request.
Alarm delay
Alarm delay
 Alarm delay
If an alarm from a selected alarm class occurs in the control unit, the alarm delay time
starts. If the triggering alarm is still going after this time has elapsed, the control unit will
trigger an ’automatic service request’ if the corresponding screen switch is activated.
243
Maintenance
Activation
Manual service-request Trigger service-request
Automatic service-Request
 Activation
A service request can be triggered both manually and automatically:
 Manual service-request
Press the [Trigger service request] button. If you confirm the following dialog, the
control unit will create a service request, including a ’text service request’.
Manual service-request
Do you want to trigger a manual service-request?
Cancel Help Execute
 Automatic service-Request
To enable this, activate the screen switch.
Text service-request
 Text service-request
An option that allows you to enter text of your choice, so that you can share additional
information with ENGEL when sending a manual service request.
Status service-request
No pending service-request
 Status service-request
The following statuses are possible:
 No pending service-request
 Service-request in process
A service request has been sent to ENGEL
 Error when reading the status and Server not available
Check your connection to the service box
If there is a faulty connection with the service box, the machine can store up to five service
requests, which the service box sends once the connection has been restored. If you try to cre-
ate another service request, the following message will appear:
ENGEL service-request
The maximum number of possible service requests has been ex-
ceeded!
OK

Maintenance
245
Maintenance

Options
Options
247
Options

Disassembly
Disassembly
Before transporting the machine, the robot and peripheral units must be dismounted. Refer to
the vendor's instructions to do so.
! WARNING!
Danger of fatal injury in case of improper dismounting!
Skilled staff are required to dismount the machine.
You must have comprehensive knowledge of safety precautions and controls!
Main switch, type plate and connections of an E-Duo machine.
249
Disassembly
1 Disconnecting
! WARNING!
Danger of fatal injury due to electrical voltage and high pressure!
A qualified electrician is required to disconnect the machine from the mains
power supply.
Switch off the mains power supply before disconnecting the machine, and
secure against switching on.
Make sure power lines have zero potential before disconnecting.
Make sure media lines have zero pressure before disconnecting.
Procedure:
1. Bring clamping unit on transport position (see also transport sketch). Open moving mold
fixing platen.
2. Switch off motor
3. Secure injection unit for the transport. [See Transportation on page 29.]
4. Block media pipings and check them for pressure freedom!
5. Disconnect cooling water
6. Blow out cooling circuits with compressed air
 Open all the flow control devices
 Open the cooling water valve
 Purge the cooling circuit with compressed air.
7. Disconnect compressed air
8. Switch off main switch
9. At the machine drain the used oil from the tank in a reservoir suitable for this purpose or
pump it into it.
10. Switch off and disconnect the power supply for the plant.
11. Disconnect electric interfaces.
12. Disconnect hydraulic interfaces. [See Transportation on page 29.]
Place oil catchment tray under the hydraulic hoses - dispose of escaping oil into the
appropriate container .
Close hydraulic hoses with hydraulic screw couplings!
13. Separate mechanical interfaces. [See Transportation on page 29.]
Information
It is very important to blow out the cooling circuits and drive motor cooling properly when the
weather is cold. Danger of frost damage!

Disassembly
2 Removal of the machine

Orderly transportation is the basis for the safety of all stakeholders and for trouble-free com-
missioning of the plant. For this reason, make sure that you observe the following instructions.
! DANGER!
Danger of fatal injury from floating loads!
Floating load hazard!
Transportation must be performed by skilled staff familiar with transportation
of machines.
 The transport sketch is in the ’chapter Plans and Protocols - Transport documents ’.
 Use appropriate lifting gear with sufficient load-bearing capacity. For weight refer to the
type plate on the machine or to the Plans and Protocols chapter (technical data, foun-
dation plan).
 Only use the marked lifting points for transportation; do not use bent or damaged lifting
gear. Check the routing of the cables from the lifting eyes to the lifting gear

At lifting points

 Modifications of the load suspension points are not permissible.

 Before the transport, please remove all moving safety gates using suitable slings
against any uncontrolled movements.
 The injection molding machine must be lifted and transported in horizontal position
(lengthwise and crosswise).
 For safe lifting of the injection molding machine, use lifting gear with 4 strands.
 Maximum spread of cables on the crane hooks 60°.
 Before lifting the machine, remove any obstructing components and use lifting gear with
edge protection if contact with the edges of neighboring components is possible.
 The clamping unit and injection unit must be secured against possible axial movement
by using the transport safety brackets provided. The rod bearings must be fully
extended. The clamping unit must be extended to the maximum mold height.
 Transportation of an injection molding machine by heavy goods vehicle is only permis-
sible if an anti-slip mat ( thickness 8 mm) is used.
 The position of the machine's center of gravity in the transport sketch may differ due to
customer options.
 The minimum capacity per lashing point on the heavy goods vehicle must be 2 t.
 Please refer to the transport sketch for machine-specific transport details, which take
priority over the standard details.
251
Disassembly
3 Disposal
NOTICE!
Environmental hazard!
Used oil and certain machine components can endanger the water supply, and
cause major environmental damage in case of improper disposal!
All machine components and parts are subject to special collection and waste disposal regu-
lations.
Make sure you observe national waste disposal regulations!

Spare parts
Spare parts
1 ENGEL manuals CD
The ENGEL manuals CD contains the entire documentation in PDF format.
It also contains the required illustrations for identifying spare parts, as well as a spare parts list
with order numbers.
The CD starts automatically when it is inserted in the PC's drive.
1
2
3
[1] Key for opening the table of contents in the indicated language
[2] PC system requirements and various notes
[3] Installation program for Acrobat Reader
253
Spare parts
2 List of spare parts

The spare parts list is used to find order numbers and is located in the ENGEL manuals CD in
the PDF format.
Component numbers on the design drawings or circuit diagrams can be used to find the cor-
responding order number in the spare parts list.
2.1 Design drawings

The construction drawings serve as examples for the identification of spare parts. These are
in the service manual machine in paper form and on the ENGEL manuals CD in PDF format.
NOTICE!
Do not use design drawings as instructions for maintenance and repair work.
The following design drawings are intended solely for the purpose of identify-
ing and ordering spare parts.
Component numbers on the drawings can be used to find the corresponding order number in
the spare parts list.
Example:
Searching for an order number for a non-return valve with component number and drawing
number of the design drawing.
1. Select the design drawing for barrels in the ENGEL manuals CD.
2. Search for and make a note of the number of the non-return valve on the design draw-
ing.
The non-return valve
has number 100 and
consists of 3 parts (100/
1, 100/2 and 100/3).
In this case, the compo-
nent number for the
barrel is not present.
3. If the component number is missing on the drawing, then make a note of the drawing
number/name for the barrel.

Spare parts
4. Open the spare parts list on the CD.

5. If the component number is missing, use the search program to search for it in the PDF
with the drawing number/name.
Search
6. In this case, the barrel component has the number 310. Now enter the component num-
ber with the number of the non-return valve in the search program. (310/100)
Search
7. The non-return valve has material number 7080-301-09-00-000, which you can use to
order the spare part.
255
Spare parts
2.2 Hydraulics schematic

The hydraulic diagram is used for troubleshooting and for identifying spare parts. It can be
found in the control cabinet in paper form and on the ENGEL manuals CD in the PDF format.
! DANGER!
Danger of fatal injury due to electric shock!
Before opening the control cabinet, switch off at main switch and secure
against switching on.
The hydraulics schematic contains not only the schematic, but also the drawings for the indi-
vidual hydraulic blocks.
The component numbers and block numbers can be used to find the corresponding order
number in the spare parts list.
Example:
Searching for an order number for a hydraulic directional valve on the pump block, with the
component and block numbers from the hydraulics schematic.
1. On the PC, open the hydraulics schematic on the machine CD.

2. Open the drawing for the pump block and identify the valve. The Engel valve number
20115194 is also the order number.
Block number
3. You can also find the valve by entering the block number in the spare parts list of the CD.
Search
Information
The hydraulic pump is not on the block drawing. The hydraulic pump is at the beginning of the
list for the hydraulic plant in the spare parts list of the CD.

Spare parts
2.3 Circuit diagram

The circuit diagram is used for troubleshooting and for identifying spare parts. It can be found
in the control cabinet in paper form and on the ENGEL manuals CD in the PDF format.
! DANGER!
Danger of fatal injury due to electric shock!
Before opening the control cabinet, switch off at main switch and secure
against switching on.
Type designations or the names of devices can be used to find the corresponding order num-
ber in the spare parts list.
Example:
Searching for an order number for a semiconductor relay for the nozzle heater.
1. On the PC, open the circuit diagram on the machine CD.

2. Open the drawing for the nozzle heater.
3. You can find the semiconductor relay by entering the type designation RM1A48 in the
spare parts list of the CD. The material number is 02206-0178.
Search
257
Spare parts
2.4 Ordering spare parts without a material number

If you are unable to determine the material number so that you can order a spare part, send
an email with the following content to your local service point:
 Machine Number
 Machine type
 Copy of drawing or schematic with the desired device highlighted.
Example: thermocouple for nozzle heater
 Photographs are also helpful for identifying spare parts.
Information
If you order spare parts by telephone, first make a note of the machine number.

Spare parts
259
Spare parts
3 e-flomo
3.1 Ball valves in the central flow and return

exchange
1
2
3
4
[1] Release button

[2] Rotary switch
[3] Plug screw connection to the electronics box
[4] Retaining pin
[5] Hole for retaining pin
Procedure
1. Pull out holding splint.
2. Pull out the drive.
3. Loosen the plug's screw connection to the electronics box.
4. Screw on plug of the new drive for the electronics box.
5. Attach the new drive.
Note whether the rotary switch of the ball valve is in the ON or OFF position:
In order to correct the position, press the release button and turn the rotary switch to the
desired position: The release button must be in Position A (automatic). Position M locks
the ball valve.
6. Slide the retaining pin completely through the hole.

Spare parts
3.2 Sensors, valves and electronics box
! WARNING!
manifold!
skin.
Overview e-flomo Premium with 6 temperature control circuits (without protective

cover)
3
1 2
8
4
7 5
6
[1] Pressure and temperature sensors in the central flow and central return
[2] Shut-off valves flow (e-flomo: manual, flomo Premium: electrical)
[3] Electrical control and shut-off valves in each return flow line
[4] Electronic box
[5] Flow rate and temperature sensors in each return flow line
[6] Side terminals to interface to the injection molding machine, to connect to another e-
flomo, and to connect the power supply
[7] Electric ball valve to lock the central flow line
[8] Electric ball valve to lock the central return line
Labeling electronics box

The arrows and labeling on the electronics box indicate the location of each terminal.
 MxR
Motor valve temperature control circuit x return flow
 MxV
Motor valve temperature control circuit x advance flow
 pVL
Pressure and temperature sensor flow
261
Spare parts
 pRL
Pressure and temperature sensor return
 Qx
Flow rate and temperature sensor temperature control circuit x
 MFL
Motor valve advance flow
 MRL
Motor valve return flow
 Power IN (24 V)
Power supply terminal
 RS485 OUT
Terminal to additional flomo manifolds
 RS485 IN
Terminal to the control unit or upstream e-flomo manifolds
Example: Labeling electronics box (e-flomo Premium with 8 temperature control cir-
cuits)
7
5
6
4
1 2 3
5 7
4 6
1 2 3
[1] Power IN (24 V): Power supply

[2] RS485 OUT
[3] RS485 IN
[4] M1R: Motor valve temperature control circuit 1 return flow
[5] M1V: Motor valve temperature control circuit 1 advance flow
[6] Q1: Flow rate and temperature sensor temperature control circuit 1
[7] Q2: Flow rate and temperature sensor temperature control circuit 2
Make the sensors, valves and electronics box accessible

You must partially or fully disassemble the safety gates to replace the sensors, valves and the
electronics box.
! WARNING!
manifold!
skin.

Spare parts
Establish zero pressure before working with the sensors, valves and the elec-
tronics box.
Purge the manifold. No water may be in the manifold anymore.
Covers
1
5
[1] Pressure sensors cover

[2] Cover valves temperature control circuits
[3] Cover front side
[4] Electronics box cover
[5] Magnetic screws
[6] Ball valves
Procedure
1. Loosen the retaining pins from the ball valves.
2. Remove the drives from the ball valves and loosen the screw connection of the plugs to
the electronics box.
3. Undo the 2 screws on the bottom of the electronics box cover and remove the cover.
4. Undo the fastening screw of the pressure sensors cover. Lift cover slightly and remove.
5. Undo the fastening screw of the front cover. Lift cover slightly and remove.
6. Loosen the magnetic screws.
7. Loosen the 2 fastening screws of the valve temperature control circuits cover and
remove covers.
Reassembling the e-flomo

1. Hook cover of valve temperature control circuits in using all 4 hooks. Fasten with the
magnetic screws and screw on with the fastening screws.
2. Hook covers of the pressure sensors and the front in with all 4 hooks and screw on each
with a fastening screw.
3. Lay the ball valve cables in the cable channel. Lay the cables so that as little cable
length as possible is accessible from outside.
263
Spare parts
4. Screw on electronics box cover with 2 screws.

5. Connect plug for the drives of the ball valves to the electronics box.
6. Mount drives of the ball valves and insert retaining cotter pins.
Replacing sensors
Information
The sensors are maintenance-free. Never attempt to clean a sensor, as this may damage the
sensor. A defective sensor must be replaced.
NOTICE!
Incorrect readings from replacing individual sensors!
The e-flomo sensors are calibrated to each other. The measurement accuracy
of the temperature and the temperature difference may be impaired when you
replace the sensors separately.
Always replace the sensors for all temperature circuits in the flow and return
together.

Spare parts
Replacing the flow rate and temperature sensors

A flow rate sensor and temperature sensor is located in the return of the respective tempera-
ture control circuit.
3
4
[1] Recess for clamp

[2] Bracket
[3] Anti-vibration ring
[4] O-ring
[5] Sensor
[6] Plug
The sensor has two sealing rings. A thin ring acts as an anti-vibration ring, and a thicker O-ring
is for sealing. A clamp is used as shown to fix the sensor.
1. Take down ball valves for advance and return flow.
2. Remove pressure sensors cover and electronics box cover.
3. Use a flat head screwdriver to pry out the ties at both sides of the sensor plug.
4. Pull the plug out.
5. Use a flat head screwdriver to pry out the clamp at the sides.
6. Pull the clamp out.
7. Pull the sensor out.
8. Insert new sensor.
Ensure correct position: Note locking recess in the bottom of the sensor head.
9. Insert clamp and push in as far as it will go.
265
Spare parts
10. Snap plug left and right into place. Listen for an audible click.
Replace the pressure and temperature sensor in the central flow or return
A pressure sensor or temperature sensor is located in the central flow or in the central return
of the e-flomo.
[1] Recess for clamp

[2] Bracket
[3] O-ring
[4] Sensor
[5] Plug
The sensor only has one O-ring for sealing. A clamp is used as shown to fix the sensor.
1. Take down ball valves for advance and return flow.
2. Remove pressure sensors cover.
3. Use a flat head screwdriver to pry out the ties at both sides of the sensor plug.
4. Pull the plug out.
5. Use a flat head screwdriver to pry out the clamp at the sides.
6. Pull the clamp out.
7. Pull the sensor out.

Spare parts
8. Insert new sensor.

Make sure it is positioned correctly. Note locking recess in the bottom of the sensor
head.
9. Insert clamp and push in as far as it will go.
10. Snap plug left and right into place. Listen for an audible click.
267
Spare parts
Replace motor valves and manual valves

Replacing the manual valve
1 1
3
4
[1] Screws
[2] Flange plate
[3] O-ring
[4] Valve spindle
1. Remove the 4 covers of the e-flomo to make the manual valves accessible.
[See Make the sensors, valves and electronics box accessible on page 262.]
2. If possible, open valves so that no forces are applied to the screws.
3. Use a long Phillips head screwdriver to loosen the 2 screws holding the flange plate.
4. Pull manual valve out of the manifold block.
Clean and then dispose of the valve.
5. Slightly grease the O-ring of the new manual valve with food-safe silicone oil. Carefully
turn spindle upwards (valve position open).
6. Insert new manual valve vertically in the interface of the manifold profile. Press in as far
as it will go.
Make sure that the valve spindle does not jam.
7. Screw flange plate on again with the 2 screws at the mounting points.

Spare parts
Replace motor valve

Motor valves are pivoting to make the screws easily accessible.
1
1
[1] Screws
[2] Flange plate
[3] O-ring
[4] Valve spindle
1. Remove the covers of the e-flomo to make the motor valves accessible.
2. Pull the motor valve plug off the electronics box.
3. Use a long Phillips head screwdriver to loosen the 2 screws holding the flange plate.
4. Pull motor valve out of the manifold block.
Clean and then dispose of the valve.
5. Make sure that the valve spindle of the new motor valve is retracted (factory setting).
6. Slightly grease the O-ring of the new motor valve with food-safe silicone oil.
7. Insert new motor valve vertically in the interface of the manifold profile. Press in as far
as it will go.
Make sure that the valve spindle does not jam.
8. Screw flange plate on again with the 2 screws at the mounting points.
9. Reestablish the electrical connection to the electronics box.
Lock motor valve manually (emergency control)

If a drive is defective or the power supply has failed, the motor valve can then be operated
using an emergency control function until a replacement is available.
269
Spare parts
2
1
[1] Holding point

[2] Screw
[3] Strap
1. Loosen the screw with a hexagon socket wrench, but do not fully unscrew.
2. Insert hexagon socket wrench at the holding point and swivel the tie to the rear as far as
it will go.
3. Pull motor valve upwards as far as it will go.
4. Swivel back tie as far as it will go with the motor valve raised.
5. Tighten the screw again with a hexagon socket wrench.
Information
When resetting the locking, pay attention to the following:
Before pressing in the motor valve against the valve seat, completely move in the valve tap-
pet.
Replacing the electronics box

1. Remove all four covers of the e-flomo to make the electronic box accessible.
2. Loosen plug connections to the electronics box.

Spare parts
3. Loosen the screws from the electronics box and take down the electronics box.
4. Screw on the new electronics box.

5. Restore electrical connections according to labeling of the electronics box.
6. Reassemble the e-flomo.
271
Spare parts

Plans and Protocols
Plans and Protocols
1 Technical data
The technical data is also provided on the CD in the PDF format.
273
Plans and Protocols

Plans and Protocols
2 Foundation plans
The foundation plan is also provided on the CD in the PDF format.
275
Plans and Protocols

Plans and Protocols
3 Transport documentation
Transport documentation is also provided on the CD in the PDF format.
277
Plans and Protocols

Plans and Protocols
4 Mold mounting dimensions

The mold mounting dimensions are also provided in PDF format on the CD.
279
Plans and Protocols

Plans and Protocols
5 Certificates
The protocols and certificates (e.g. EC Declaration of Conformity, Declaration of Incorporation,
noise measurement report, ...) are only in the service manual.
281
Plans and Protocols

Plans and Protocols
6 Pressure accumulator test certificate

The test certificate is also provided on the CD in the PDF format.
283
Plans and Protocols

Additional equipment
If vendor documentation is required due to a special version or special equipment on the injec-
tion molding machine, the appropriate description will follow in this chapter or on CD!
285

Special programs
Special programs
287
Special programs

Index
Index *MuCellT x: pump maintenance required 171

*MuCellT x: rupture disc broken 172
*MuCellT x: System test failed - Wrong flow coefficient set 173
*MuCellT x: Warning Bit 14 171
*MuCellT x: Warning Bit 15 174
*No oil filtration 233
Symbols *No oil temperature change 230, 231
*Additional contactor acknowledgement safety gate nozzle x *Nozzle contact limit switch defective 188
acknowledged defective 195 *Nozzle safety gate x defective 186
*Additional contactor acknowledgement safety gate nozzle x *Nozzle stroke limitation x 150
not acknowledged defective 195 *Nozzle stroke transducer faulty 151
*Additional contactor Fencing safety gate x closed defective *Nozzle x swivelled out 191
194 *Oil filtration active 234
*Additional contactor Fencing safety gate x open (closing safe- *Oil level too low 56, 221
ty) defective 194 *Oil temperature too high 230
*Additional contactor Fencing safety gate x open defective 194 *Oil temperature too low for automatic mode 229
*Additional contactor mounting aid x Assembly place ack- *Pull rods nozzle x too short 151
nowledged defective 195 *Pump venting mode => set-up mode 54, 219
*Additional contactor mounting aid x Assembly place not ack- *Safety gate x safety strip actuated 185
nowledged defective 195 *Safety gate x safety strip opening actuated 185
*Additional contactor mounting aid x in operation position de- *Tank shut off valves closed 223
fective 195 *Venting Pumpx active 54, 219
*Additional contactor mounting aid x not in operation position
defective 195 A
*Additional contactor safety gate x acknowledged defective Additional equipements 21
194 Align mold fixing platens 47
*Additional contactor safety gate x closed defective 194 Ambient conditions 27
*Additional contactor safety gate x not acknowledged defective Applicable European standards and regulations 23
194 Assemble the barrel 147
*Additional contactor safety gate x open (closing safety) defec- Auxiliary flow filtration 234
tive 194
*Additional contactor safety gate x open defective 194 B
*Additional contactors safety strip x defective 194 Barrel cleaning 145
*Barrel heating x Feedthroat x no recognizable temperature in- Behavior in case of fire 22
crease 168 Bladder accumulator 235
*Barrel heating x Feedthroat x recognizable temperature drop Blow out cooling water 123
168
*Check e-flomo x water supply manifold x 65 C
*Check high-pressure filter 233
Calibrating the nozzle stroke 152
*Check oil filter 233
Centering of mold 113
*Check return filter 233
Certificates 281
*Clamping unit maintenance safety gate x actuator defective
Change hydraulic oil 216
189
Change oil of the plasticizing drive 205
*Clamping unit maintenance safety gate x open - close 190
Change the hydraulic oil from zinc-containing to zinc-free 222
*Clamping unit safety gate x open-close 185
Changing a nozzle 134
*Clamping unit safety gates sum contactors x defective 194
Check and fill the bladder accumulator 235
*Compressed air monitoring machine circuit x 70, 241
Check and fill the diaphragm accumulator 237
*Contact point not within stroke limits 150
Check direction of rotation main connection 60
*Contactor monitoring nozzle x closed defective 195
Check machine - EVER-Q 163
*Contactor monitoring nozzle x open defective 195
Checking the coaxiality of the two mold halves 120
*Hydraulic closing safety defective 186
Circuit diagram 257
*Hydraulic closing safety x cartridge defective 186
Clean air filter 166
*Impermissible heating pump x 231
Clean cooling water filter 167
*Internal error occurred: Wrong cube-version -> contact EN-
Cleaning after installation 57
GEL 84
Cleaning notes 57, 164
*Internal error occurred: Wrong kecontrol-version -> contact
Cleaning of machine 164
ENGEL 84
Cleaning the control panel on the ENGEL control unit 165
*License expires in x days 84
Commissioning 71
*Maintenance interval x 158
Commissioning the injection molding machine 71
*Mounting aid acknowledgement contactor defective 188
Compressed air monitoring 70, 241
*Mounting aid defective 187
Compressed air quality 69
*MuCell x: Booster pump 1 maintenance interval reached (per-
Compressed air supply (maintenance unit) 68
form service) 176
Compressed-air line 68
*MuCellT x: Boost pressure too low 174
Connecting the frames of the clamping unit and the injection
*MuCellT x: Compressor high duty cycle - leak 172
unit 40
*MuCellT x: Compressor high duty cycle - seals 172
Contact multiplication safety gates 194
*MuCellT x: Compressor low oil pressure 172
Cooling water quality 61
*MuCellT x: Compressor maintenance required 171
Correct crane lifting of molds 111
*MuCellT x: Compressor pressure ramp too low 172
Correct mounting the mold 115
*MuCellT x: Pressure test failed 173, 174
289
Index
Coupling the injection unit on the stationary mold fixing platen Maintenance EMERGENCY STOP buttons 182
42 Maintenance interval 1 159
Maintenance interval 2 160
D Maintenance interval 3 161
Danger signs 16 Maintenance interval 4 162
Declaration of incorporation 281 Maintenance intervals 157
Design drawings 254 Maintenance MuCell Sll 175
Disconnecting cooling water 250 Maintenance of the safety devices 182
Dismantle the barrel 145 Maintenance safety gate 189
Dismantling the nozzle 134 Maintenance schedule 159
Disposal of the machine 252 Maintenance unit 240
Mandatory Signs 16
E Manometer 228
Measuring positions nozzle centering 101
EC declaration of conformity 281
e-flomo 63, 260 Mold anti-twist safeguard (rotational centering) 114
Mold mounting dimensions 279
e-flomo Blowing-out cooling water 123
Mount mold 109
e-flomo cooling water connection 64
e-flomo electrical connection 66 Mounting aid 187
Mounting of both mold halves 115
e-flomo Replacing ball valves 260
Mounting of individual mold halves 117
e-flomo Replacing sensors 264
e-flomo Replacing valves 268 Mounting the nozzle 136
MuCell maintenance 170
Electrical connections 59
MuCell maintenance T-series 170
EMERGENCY STOP buttons 182
ENGEL manuals CD 253 MuCell pressure test 180
MuCell system test 179
MuCell Test Sll 177
F MuCell test T-series 173
Factors affecting mold performance 118
Fill hydraulic oil 49, 217
Fixed gate for delivery chute 193
N
Network connection 60
Food-safe lubricants and hydraulic oils (NSF-H1) 214
Foundation plans 275 Noise emission report 281
Nozzle centricity 100
Foundations 28
Nozzle stroke limitation 150
G
Guidelines for working on the injection molding machine 17
O
Oil cooler 232
Oil filter 233
H Oil temperature control 229
HD hose nut tightening torque 225
Operating pressure compressed air 68
Hose safety catch 227 Operating pressure compressed air to set 68
Hoses for the pneumatic system 242
Options 247
Hours of operation 157
Ordering spare parts without a material number 258
Hydraulic closing safety 186 Overview lubricants and hydraulic oils 210
Hydraulic lines 224
Overview of lubricants circulating oil 214
Hydraulic oil overview 50
Hydraulic oils 212
Hydraulic system 223
P
Pictographs 15
Hydraulics 215
Pressure accumulator test certificate 283
Hydraulics schematic 256
Prohibitory signs 15
Proper Use 9
I
Influencing factors of the injection molding machine on mold
closing behavior 122
R
Install barrel 133 Removal of the H-injection unit's transport clamps 34
Removal of the machine 251
Installation 30
Removal of the transport safety brackets at the pull rods 37
Installing of flange 142
Remove barrel 127
Remove the clamping unit transport safety brackets 38
L Removing of flange 140
Leveling the injection molding machine 43
Removing the injection unit transport safety brackets 34
Lubricant 210 Replacement of barrel flange 139
Lubricate guide carriage 199
Rescue actions 23
Lubricate guide carriage - safety gate 200
Residual dust content 69
Lubricate pivot mount 197 Residual oil content 69
Lubricate the high-speed clamping cylinder 198
Residual water content 69
Lubricate tiebar pulling device (optional) 201
Lubrication 196
Lubrication Clamping unit 197
S
Safety conformity 24
Safety distance to the fixed equipment 33
M Safety hints 17
Machine labeling 18 Safety limit switch for swiveling out injection unit 191

Index
Service application - Functions 76

Service application - Info bar 75
Service Application - Keypad 77
Service application - Main menu 75
Service application - Screen layout 74
Service application - Setting range 76
Service Request 24 243
Serviceapplication 73
Setting up the barrel 125
Spare part drawings 254
Structure of the system documentation 7
T
Tank shut-off flap 223
Technical data 273
Temperature control device 98
Text formatting 10
Tightening torque heater band 138, 144
Tightening torque nozzle 138
Tightening torques barrel flange 148
Transport documentation 277
Transportation 29
Type plate 20
V
Valve cleaning crossbar cooling 168
Vent hydraulic system 56, 221
Vent the pump 53, 218
Venting a pressure pad 96
Visual check 155
W
Water temperature 61
291
Index

294
ENGEL Austria GmbH | 4311 Schwertberg | tel: +43 (0)50 620 0 fax: +43 (0)50 620 3609
e-mail: service@engel.at | www.engelglobal.com

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DUO 2460/500

Serial No.: 219571

Service Manual - Machine

ENGEL AUSTRIA GmbH

Person responsible for documentation: Harald Pichler

Translation of original instruction manual

Structure of the system documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

17.2.2.6 User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Setting up for injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4 Service Manual - Machine | Version G/11/30/35/11

6.2.7 Gear assembly oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Plans and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Special programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6 Service Manual - Machine | Version G/11/30/35/11

Structure of the system documentation

Instruction Manual - Machine

Operator Manual - Machine (Operation)

Service manual - Machine (Commissioning, Maintenance)

ENGEL Manual CD contains the following documents in PDF format:

Instruction Manual - Robot

Operator Manual - Robot (Operation)

Service manual - Robot (Commissioning, Maintenance)

ENGEL Manual CD contains the following documents in PDF format:

A plan of the electric system is located in the control cabinet.

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3.1 Occupational safety

 Trained operations staff

ENGEL user role: production staff

 Qualified operations staff

ENGEL user role: installer, quality manager

 Qualified specialist staff

ENGEL user role: process technician, maintenance engineer, all rounder

Activity Trained opera- Qualified opera- Qualified spe-

User level 3 User level 7-9 User level 11

Switch on and shut down

Simple tasks during nor-

Simple adjustments and

Appropriate training is available on www.engelglobal.com/training and at the ENGEL

3.3 Personal protection gear

Observe local safety regulations for operating injection molding machines!

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3.4 Place of work

3.5 Thermal hazards

3.6 Mechanical hazards

3.7 Gases, vapors and dusts

3.9 Setup work

ENGEL is not liable for operator errors.

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Symbol Description and examples of labels

Admittance for authorized persons only!

Keep off the area!

No admittance for persons with cardiac pacemaker!

Working or standing below moving components and suspended loads is prohib-

No fork lift trucks!

Filling with zinc-based hydraulic oil not permitted!

Symbol Description and examples of labels

Use protection equipment!

Use face protection!

Use safety belt!