Husky hypet 400

HyPET Injection Molding Machine Operator Manual

Original Instructions

HyPET Injection Molding Machine

Issue:

v 2.6 — April 2012

This product manual is intended to provide information for safe operation and/or maintenance. Husky reserves the right to make changes to products in an effort to continually improve the product features and/or performance. These changes may result in different and/or additional safety measures that are communicated to customers through bulletins as changes occur. This document contains information which is the exclusive property of Husky Injection Molding Systems Limited. Except for any rights expressly granted by contract, no further publication or commercial use may be made of this document, in whole or in part, without the prior written permission of Husky Injection Molding Systems Limited. Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission to its customers to reproduce this document for limited internal use only. Husky® product or service names or logos referenced in these materials are trademarks of Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies under license. All third-party trademarks are the property of the respective third-party and may be protected by applicable copyright, trademark or other intellectual property laws and treaties. Each such third-party expressly reserves all rights into such intellectual property. © 2008-2012 Husky Injection Molding Systems. All rights reserved.

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Operator Manual

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General Information Equipment Identification

1

2 3 4

SUPPLY No.1 LOAD

V

LARGEST MOTOR

A

TOTAL HEAT LOAD

A

SUPPLY No.2 LOAD

V

LARGEST MOTOR

A

TOTAL HEAT LOAD

A

SUPPLY No.3 LOAD

V

LARGEST MOTOR

A

TOTAL HEAT LOAD

A

Hz

System

SHORT-CIRCUIT INTERRUPTING CAPACITY

A

Hz

SHORT-CIRCUIT INTERRUPTING CAPACITY

Hz

A

kA System

kA

System

SHORT-CIRCUIT INTERRUPTING CAPACITY

kA

5

MACHINE MODEL SERIAL NUMBER CERTIFICATION

MO/YR OF MFG. ELECTRICAL DIAGRAM HPN 3213627

Figure 1

A

R HUSKY INJECTION MOLDING SYSTEMS LTD.

BOLTON, ONTARIO, CANADA L7E 555

Nameplate Location (Typical)

1. Machine Nameplate 2. Model Number 3. Serial Number 4. Warranty Start Date 5. Certification Symbols

Telephone Support Numbers North America

Toll free

1-800-465-HUSKY (4875)

Europe

EC (most countries)

008000 800 4300

Direct and Non-EC

+ (352) 52115-4300

Toll Free

800-820-1667 or +800-4875-9477

Direct:

+86-21-3849-4520

Brazil

+55-11-4589-7200

Mexico

+52-5550891160 option 5

Asia

Latin America

For on-site service, contact your nearest Husky Regional Service and Sales office. For non-emergency questions and issues you may also e-mail Husky at [email protected]. General Information

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Ordering Additional Manuals Additional copies of this manual and other documentation can be purchased through your nearest Husky Regional Service and Sales office.

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Ordering Additional Manuals

Operator Manual

v 2.6 — April 2012

Table of Contents

Table of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Telephone Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Ordering Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Chapter 1:

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 1.2 1.3 1.4 1.5

Purpose of the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.5.1 Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.5.2 Drawings and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.5.3 Safety Alert Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.6 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.7 Machine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Chapter 2:

Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1 2.2 2.3

Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.3.1 Mechanical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.3.2 High Pressure Leak Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.3.3 Burn Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.3.4 High Pressure Explosion Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.3.5 Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.3.6 Noise Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3.7 Gas, Vapor and Dust Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3.8 Slip, Trip or Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3.9 Lifting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.4 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.5 Guards and Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.6 Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.6.1 Performing Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.6.2 Removing Locks and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.7 Personal Protective Equipment and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.7.1 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 v

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2.7.2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.8 Material Safety Data Sheet (MSDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.9 Materials, Parts and Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.10 Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.10.1 Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.10.2 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.10.3 Product Handling Gate Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.10.4 Safety Gates and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.10.5 Mechanical Safety Device (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.10.6 CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.10.7 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.10.8 Manual Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.10.9 Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.10.10 Electrical Cabinet Door Interlocks and Override (UL only) . . . . . . . . . . . . . . . . . . 25

Chapter 3:

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Chapter 4:

Human Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.1 4.2 4.3

Access Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Default User Name and Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Logging On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4.3.1 Logging On With a Datakey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4.3.2 Logging On With a Username and Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4.4 Logging Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 4.5 General Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4.5.1 Sidebar Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5.1.1 Accessing the Function Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5.1.2 Standard Sidebar Function Groups and Sidebar Icons . . . . . . . . . . . . . . . . . 35 4.5.1.3 Function Group, Function and Process Value Icons Explained . . . . . . . . . 37 4.5.2 Cycle Mode Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4.5.3 Robot Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 4.5.4 Pump Motor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 4.5.5 Main Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.5.6 Screen Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.5.7 Manual Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.5.8 Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.5.9 Common Screen Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.5.9.1 Alphanumeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.5.9.2 Numeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.5.9.3 Common Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.6 Setting the Machine Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.7 Generating On-Demand and Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.7.1 Report Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 vi

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4.7.2 Generating On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.7.3 Enabling Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.7.4 Viewing Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.7.5 Printing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.7.5.1 Printing On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 4.7.5.2 Printing Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 4.7.6 Saving Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 4.7.6.1 Saving On-Demand Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 4.7.6.2 Saving Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 4.8 Graphing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 4.8.1 Common Graphing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 4.8.2 Generating a Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 4.9 Assigning Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 4.10 Enabling/Disabling the Booster Cylinders (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . 57

Chapter 5:

Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.1 Inspecting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5.2 Powering Up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5.3 Logging On to the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.4 Checking the Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5.5 Checking the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5.6 Checking and Resetting the Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5.7 Warming the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.8 Checking the Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 5.9 Checking the Product Handling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 5.10 Checking/Enabling the Mold Related Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.11 Cycling the Machine and Product Handling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12 Turning On the Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12.1 Turning on the Machine, Mold and Nozzle Tip Heats (RS80/80). . . . . . . . . . . . . 68 5.12.1.1 Turning on the Machine Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 5.12.1.2 Turning on the Mold Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5.12.1.3 Turning on the Nozzle Tip Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 5.12.2 Turning on the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 5.12.3 Enabling Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 5.12.4 Configuring the Temperature Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.12.4.1 Configuring an Individual Temperature Setpoint for a Machine or Mold Heat Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.12.4.2 Configuring Individual Temperature Setpoints for Nozzle Tip Heat Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 5.12.4.3 Configuring a Global Temperature Setpoint for Machine or Mold Heat Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 5.12.4.4 Configuring a Global Temperature Setpoint for Nozzle Tip Heat Zones 82

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5.13 Preparing the Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5.13.1 Opening the Process Material Feed Manual Shutoff (If Equipped) . . . . . . . . . . 84 5.13.2 Opening the Process Material Feed Auto-Shutoff (If Equipped). . . . . . . . . . . . . 84 5.13.3 Opening the Magnet Drawer (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 5.14 Purging the Injection Unit Before Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 5.15 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen. . . . . . . . . . . 86 5.16 Inspecting the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 5.17 Precharging the Hot Runner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 5.18 Producing Test Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 5.19 Setting Up SmartStart (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 5.20 Setting Up SmartStop (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 5.20.1 Stopping on a Critical Machine Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 5.20.2 Stopping After Producing Extra Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 5.20.3 Stopping After Completing Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 5.20.4 Stopping on a Specific Day and Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 5.21 Starting Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.21.1 Starting Production Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.21.2 Starting Production with SmartStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 6:

Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

6.1 6.2 6.3

Stopping the Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Pausing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Stopping the Machine in a Controlled Manner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 6.3.1 Stopping Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 6.3.2 Shutting Off the Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 6.3.3 Purging the Injection Unit After Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 6.3.4 Turning Off All the Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 6.3.4.1 Turning Off the Machine, Mold and Nozzle Tip Heats (RS80/80) . . . . . .107 6.3.4.1.1 Turning Off the Machine Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 6.3.4.1.2 Turning Off the Mold Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 6.3.4.1.3 Turning Off the Nozzle Tip Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 6.3.4.2 Turning Off the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 6.3.5 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen . . . . .110 6.3.6 Emptying the Hopper/Direct Feed Tube (Optional) . . . . . . . . . . . . . . . . . . . . . . .110 6.3.7 Cleaning the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 6.3.8 Turning Off Mold Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 6.3.9 Turning Off the Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 6.3.10 Powering Down the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 6.4 Unexpected Machine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Chapter 7: 7.1 viii

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

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7.1.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 7.1.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 7.1.3 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 7.2 Draining the Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 7.3 Cleaning the Nozzle Tip, Stationary Platen and Purge Guard . . . . . . . . . . . . . . . . . . .123 7.4 Checking the Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 7.4.1 Checking the Emergency Stop Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 7.4.2 Checking the Safety Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 7.4.3 Checking the Mechanical Safety Device (If Equipped) . . . . . . . . . . . . . . . . . . . . .127 7.4.4 Checking the Automatic Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 7.4.5 Checking the Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 7.4.6 Checking the CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 7.5 Cleaning the Machine and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 7.6 Checking the Hydraulic Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 7.7 Purging the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 7.7.1 Manually Purging the Injection Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 7.7.2 Auto Purging the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 7.8 Changing the Resin Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

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Chapter 1

Introduction

Introduction This chapter describes the machine, training opportunities, and the available equipment manuals.

1.1

Purpose of the Equipment Husky equipment and systems are designed for injection molding applications only, using approved materials and operating within design guidelines. Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky product for anything other than its intended use.

1.2

Restrictions of Use Husky injection molding equipment must never be: • • • • •

1.3

used for any purpose other than that described in Section 1.1, unless otherwise approved by Husky used to extrude metal or food compounds operated or serviced by personnel unfamiliar with the inherent risks and necessary precautions related to injection molding equipment operated at temperatures higher than the maximum presumable temperature for plasticizing operated by more than one person

Unauthorized Modifications Unauthorized modifications or reconstruction of any Husky injection molding system is strictly prohibited. Modifications, such as the substitution or removal of components, can be unsafe and/or void warranty. Contact your nearest Husky Regional Service and Sales office to discuss modifications or requirements for Husky systems.

Purpose of the Equipment

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Auxiliary Equipment Husky is only responsible for the interaction of Husky equipment and systems with auxiliary equipment when Husky is the system integrator. If auxiliary equipment is removed, proper safeguards must be installed. For information about integrating non-Husky auxiliary equipment, contact your nearest Husky Regional Service and Sales office.

1.5

Documentation Each Husky machine is delivered with a Documentation CD that contains a full set of manuals, drawings, certificates and other documentation needed by operators and service technicians. Documentation is also available online through www.husky.ca. Printed manuals and drawings from the Original Equipment Manufacturers (OEMs) are also provided with the machine when available.

IMPORTANT! If a Husky mold is equipped, refer to the separate Documentation CD provided with the mold for operation, installation and service information.

IMPORTANT! Keep all CDs and printed documentation in a convenient location for future reference.

1.5.1

Manuals Husky manuals aid in the safe and proper use of Husky products. Where applicable, the manuals provide instructions on installation, operation and maintenance. Personnel should thoroughly review all manuals provided with their Husky equipment prior to performing any tasks. Proceed with tasks only if all instructions are understood and always follow applicable workplace safety requirements. The following manuals are provided with each Husky machine upon delivery:

2

Site Preparation Manual

Describes preparing the site and receiving/handling the machine

Operator Manual

Describes operator controls, startup and shutdown procedures, production controls, and daily maintenance requirements

Service Manual

Includes specifications and requirements, installation procedures, scheduled maintenance procedures, corrective maintenance procedures and troubleshooting

Auxiliary Equipment

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Introduction

IMPORTANT! Some manuals may contain addendums that detail new or updated information. Before reading a manual, make sure to review all available addendums located at the end of the manual.

1.5.2

Drawings and Schematics Each Husky machine is provided with a set of drawings and schematics specific to the machine. These are used for troubleshooting the machine and ordering spare parts.

NOTE: Each drawing and schematic is specific to the machine it is provided with.

1.5.3

Safety Alert Conventions Safety alerts highlight hazardous conditions that may arise during installation, operation or maintenance and describe methods for avoiding personal injury and/or property damage. Depending on the severity of the hazard, safety alerts start with one of the following signal words: Danger, Warning or Caution.

DANGER! The DANGER safety alert indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING! The WARNING safety alert indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION! The CAUTION safety alert indicates a potentially hazardous situation that, if not avoided, could result in property damage. Other non-safety related alert types used in the manuals highlight important information needed by the user to install, operate or maintain the machine properly. They may also, in some cases, describe best practices, offer an expanded explanation, or reference a related section in the manual. Non-safety related alerts start with one of the following signal words: Note, Important, or Reminder.

NOTE: The NOTE alert is used to add information to a subject that does not fit within the general flow of the document.

Drawings and Schematics

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IMPORTANT! The IMPORTANT alert is used to highlight important steps, conditions, or considerations related to the subject.

1.6

Training All designated operators and maintenance personnel must be fully trained before using or servicing Husky injection molding systems. If training is required, visit www.husky.ca or contact your nearest Husky Regional Service and Sales office to learn more about Husky’s training solutions.

IMPORTANT! It is the obligation of the employer to properly train and instruct all personnel in safe methods of operation and maintenance. Manuals and other reference material, which have been prepared by Husky for the operation and maintenance of Husky equipment, do not in any way absolve the employer from fulfilling these obligations and Husky disclaims liability for injury to personnel which is attributable to the employer's failure to do so.

1.7

Machine Layout Throughout this manual and other documentation provided with the machine, references will be made to specific areas of the machine. The illustration below describes these areas and the standard terminology used to reference them.

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Training

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6

7

Figure 1-1

Machine Orientation (Typical)

1. Clamp End 2. Non-Operator Side 3. Injection End 4. Operator Side 5. Clamp Unit and Product Handling Area 6. Injection Unit 7. Operator Work Area

Machine Layout

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Chapter 2

Safety Summary

Safety Summary This chapter describes the general requirements and conditions for safe operation of the machine.

IMPORTANT! Personnel must read, understand and follow all safety precautions.

IMPORTANT! Personnel must follow applicable industry and regulatory safety requirements for safe installation, operation and maintenance of equipment.

2.1

Qualified Personnel Only fully trained and qualified personnel should be permitted to operate equipment. Qualified personnel must have demonstrated skills and knowledge related to injection molding equipment, as well as training to recognize potential hazards.

2.2

Safety Guidelines Personnel operating, installing, maintaining or servicing Husky equipment must adhere to safe working practices that are in compliance with the following guidelines: • • • • • • •

Qualified Personnel

Use an appropriate ladder or platform to access areas of the machine. Lockout and tag electrical, pneumatic and hydraulic energy sources before servicing the machine or entering the mold area. Depressurize the hydraulic system using the manual dump valve before servicing any hydraulic component. Do not climb over Husky equipment while the machine is in operation. Do not operate the machine unless all guards are in place. Do not operate the machine if a safety interlock is bypassed, modified or damaged. Do not operate the machine if any component or system is missing or damaged.

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HyPET Injection Molding Machine

Do not operate the machine if scheduled preventive maintenance has not been performed. Do not use a magnetic platen without approval from Husky and the magnetic platen supplier/manufacturer.

Safety Hazards Some common safety hazards associated with injection molding equipment are: • • • • • • • • •

2.3.1

Mechanical (pinching, shearing, crushing) High Pressure Leak Burn Explosion Electrical Noise Gas, Vapor and Dust Emissions Slip, Trip or Fall Lifting

Mechanical Hazards •

Worn Hoses and Safety Restraints Regularly inspect and replace all flexible hose assemblies and restraints.

•

Cooling Water Hoses Cooling water hoses degrade over time and need to be replaced on a yearly basis. Cooling water hoses routed in the vicinity of the barrel are exposed to high temperatures that shorten their useful life and can require more frequent replacement. Degraded hoses become brittle and can break or separate from the fitting when manipulated. To minimize the risk of failure, inspect the hoses regularly and replace as required. Make sure to wait until the machine has cooled down before servicing cooling water hoses.

•

8

Injection and Clamp Units Hydraulic circuits in injection and clamp units contain high pressure accumulators. Before servicing hydraulic systems, lock out and tag the machine to discharge all stored energy. When servicing hydraulic systems, read the equipment manuals and refer to hydraulic schematics for additional details.

Safety Hazards

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High Pressure Leak Hazards •

Hydraulic System Flexible hose connections and piping in hydraulic systems must be properly tightened to prevent the release of fluids or gases under pressure. Hoses must be inspected periodically for signs of sweating and/or blistering. Steel tubes should be tested using dye penetrant.

WARNING! High pressure spray hazard – risk of death or serious injury. High pressure hydraulic oil spray can penetrate human tissue and cause extensive injuries. Lock out and tag the machine before servicing any hydraulic component. •

2.3.3

2.3.4

Skin Puncture Injuries High pressure hydraulic spray can penetrate human tissue and cause severe bodily injury. Seek immediate medical help in any event of skin puncture by fluid spray.

Burn Hazards •

Hot Surfaces The mold area, auxiliary mold equipment, and injection unit heating elements have numerous high temperature surfaces. At normal operating temperatures, contact with these surfaces will cause severe skin burns. These areas are clearly marked with safety signs. Wear personal protective equipment when working in these areas.

•

Molten Material Never touch process material purged or otherwise flowing from the nozzle, mold, hot runner or feed throat area. Molten material can appear cool on the surface, but remain very hot on the inside. Wear personal protective equipment when handling purged material.

High Pressure Explosion Hazards Pressure can build up in a nozzle or feed throat area and cause some process material to explode. In some cases, molten material can be ejected unintentionally due to insufficient pre-drying or degradation of process materials. These areas are clearly marked with safety signs. Be aware of these areas. Wear appropriate personal protective equipment when accessing these areas.

2.3.5

Electrical Hazards Molding equipment draws high power. The electrical requirements are indicated on the electrical nameplate on the electrical cabinet, and in the electrical schematics. Connect equipment to a suitable power supply as specified in the electrical schematics and in compliance with all applicable local regulations.

High Pressure Leak Hazards

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Noise Hazards When the machine is at idle, the average noise level in the operator’s work area is 85 dB(A), as measured according to DIN 45 635-T1-Class 2. The peak noise level will vary depending on processing conditions.

WARNING! All personnel in the machine area must wear appropriate hearing protection if noise emission levels exceed 85 dB(A). Prolonged exposure to excessive noise levels can cause hearing loss. Make sure noise levels are in compliance with all applicable local regulations.

2.3.7

Gas, Vapor and Dust Emissions Certain processed materials release harmful gas, vapors or dust. Install an exhaust system according to local codes.

2.3.8

Slip, Trip or Fall Hazards Do not walk, stand, climb or sit on machine surfaces. Use an approved platform or walkway around equipment to reach areas that are not accessible from the floor.

2.3.9

Lifting Hazards When lifting equipment, use suitable lifting devices, proper balancing techniques and designated lifting points. Refer to the installation details for handling and lifting instructions. Do not exceed the rated capacity of the lifting equipment.

2.4

Safety Signs Safety signs clearly mark potentially hazardous areas in or around equipment. For the safety of personnel involved in equipment installation, operation and maintenance, use the following guidelines: • • • •

10

Verify that all signs are in the proper locations. Refer to the drawing package for details. Do not alter signs. Keep signs clean and visible. Order replacement signs when necessary. Refer to the drawing package for part numbers. Noise Hazards

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Safety Summary

The following safety symbols may appear on safety signs:

NOTE: Safety signs may include a detailed explanation of the potential hazard and associated consequences. Safety Symbol

General Description of Symbol General This symbol indicates a potential personal injury hazard. It is usually accompanied by another pictogram or text to describe the hazard.

Hazardous Voltage This symbol indicates a potential electrical hazard that can cause death or serious injury.

Molten Material and/or High Pressure Gas This symbol indicates the presence of a molten material or high pressure gas hazard that can cause death or severe burns.

Lockout/Tagout This symbol identifies an energy source (electrical, hydraulic or pneumatic) that must be de-energized before maintenance is performed.

Crushing and/or Impact Points This symbol indicates a crushing and/or impact area that may cause serious crushing injury.

High Pressure This symbol indicates a heated water or steam hazard that may cause severe burns.

High Pressure Accumulator This symbol indicates the sudden release of high pressure gas or oil can cause death or serious injury.

Hot Surfaces This symbol identifies the presence of exposed hot surfaces that will cause serious burn injuries.

Slip, Trip or Fall Hazard This symbol indicates a slip, trip or fall hazard that can cause injury.

Safety Signs

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General Description of Symbol Crushing Hazard This symbol indicates the presence of a crushing hazard at the rotating screw that can cause serious injury.

Read Manual Before Operation This symbol indicates that qualified personnel should read and understand all instructions in the equipment manuals before working on the equipment.

Class 2 Laser Beam This symbol indicates a laser beam hazard that can cause serious injury with prolonged exposure.

Barrel Cover Grounding Strap This symbol indicates an electrical hazard related to the barrel cover grounding strap that can cause death or serious injury.

2.5

Guards and Interlocks Guards are provided where hazards exist. There are two types of guards: movable and fixed. Movable guards are interlocked to stop hazardous motion when the guards are moved or removed. Fixed guards are not interlocked. Fixed guards must be installed and completely secured anytime power is applied to the machine.

IMPORTANT! Before operating the equipment, make sure of the following: • • • •

12

Safeguards are in place Safeguards are not bypassed or modified Safeguards are tested and inspected regularly for correct operation Only qualified personnel perform maintenance tasks

Guards and Interlocks

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Safety Summary

Lockout/Tagout Lockout/tagout must be performed on the complete system before performing any maintenance tasks or entering the mold area. Lockout/tagout includes de-energizing all systems, isolating all energy sources, and applying locks and tags to all energy sources.

IMPORTANT! For detailed lockout/tagout instructions for auxiliary equipment refer to the original equipment manufacturer's documentation, along with all applicable local regulations and codes.

IMPORTANT! When troubleshooting electronics, lockout/tagout may not be possible. In this case, service personnel must secure the work cell by installing a Danger sign at all isolation points and cordoning off the area around the equipment.

2.6.1

Performing Lockout/Tagout WARNING! Hazardous – risk of death or serious injury. Before starting the lockout/tagout procedure, read and understand the entire procedure. Failure to perform the lockout/tagout procedure correctly, before performing any service and/or maintenance activities, could result in death or serious injury. To lock out and tag the machine, do the following:

DANGER! Electrocution hazard – risk of death or serious injury. Install a danger sign at all isolation points and block off the area around the machine. When live troubleshooting is required, do not work alone. Have emergency medical assistance nearby throughout the procedure.

WARNING! Electrocution hazard – risk of death or serious injury. Exposure to an electric arc flash could cause second degree burns. Wear arc rated personal protective equipment conforming to the National Fire Protection Association standards, or the equivalent local arc flash regulations.

Lockout/Tagout

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WARNING! Hazardous voltages, high pressure fluids, crushing or impact hazards – risk of death or serious injury. Perform the lockout/tagout procedure in accordance with local codes. Only qualified personnel should lock out and tag the machine. 1.

If equipped, move the Q3M breaker switch to the OFF position. This turns off power to motion control. 3

4

1

2 5

Figure 2-1

Breaker Switches (Typical)

1. Toggle Switch (If Equipped) 2. Rotary Switch (If Equipped) 3. Q2M Breaker Switch 4. Q1M Breaker Switch 5. Q3M Breaker Switch (If Equipped)

NOTE: For machines shipped to European countries with the integrated mold heats option, the Q1M breaker controls power to the machine, Human Machine Interface (HMI) and mold heats. 2.

Move the Q2M breaker switch to the OFF position. This turns off power to the integrated mold heats.

CAUTION! Electrical hazard – risk of component damage. When powering down the machine, switch off the Q3M (if equipped) and Q2M breaker switches before switching off the Q1M breaker switch. Failure to do so can result in unnecessary wear on components and lead to premature failure.

14

3.

Move the Q1M breaker switch to the OFF position. This turns off power to the machine and HMI.

4.

Attach a lock and tag to each breaker switch and wait 10 minutes for residual voltage to discharge.

5.

Using a calibrated voltmeter, make sure all power to the machine is switched off.

Performing Lockout/Tagout

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Safety Summary

WARNING! Trapped hydraulic pressure - risk of serious injury. After depressurizing the hydraulic system, and locking and tagging any energy source, verify that all pressure has been discharged before servicing the machine. 6.

On the power manifold, remove the gauge port cap and attach a hydraulic pressure gauge to each gauge port used to measure hydraulic pressure in the accumulators. The gauge must be rated for pressures higher than the machine operating pressure and have a quick disconnect fitting. Refer to the hydraulic schematic for the specific location of the gauge port(s).

7.

At the power manifold, turn each manual dump valve counter-clockwise to make sure the accumulator(s) discharge.

2

1

Figure 2-2

Manual Dump Valve (Typical)

1. Power Manifold Assembly 2. Manual Dump Valve

WARNING! Trapped hydraulic pressure hazard – risk of serious injury. Some hydraulic circuits, other than the accumulator circuit(s), may be designed to contain hydraulic pressure when the machine has been shut down. Make sure to relieve pressure from these circuits before performing any maintenance on related components. 8.

Check the hydraulic pressure gauge to verify the accumulator is completely discharged.

9.

Turn the shutoff lever on the air regulator to turn off the compressed air supply.

10. Attach a lock and tag to the shutoff lever.

Performing Lockout/Tagout

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2

3

4

Figure 2-3

Air Regulator With Lock and Tag (Typical)

1. Air Regulator 2. Shutoff Lever 3. Lock 4. Tag

2.6.2

Removing Locks and Tags To remove locks and tags from the machine, do the following: 1.

Make sure a hydraulic pressure gauge or cap is in place for all gauge ports.

2.

Make sure all power cables are properly connected.

3.

Make sure all personnel are outside the safety barriers.

WARNING! Hazardous voltages, high pressure fluids, crushing or impact hazards – risk of death or serious injury. Follow local codes when removing locks and tags. Only qualified personnel should lock out and tag the machine.

IMPORTANT! Locks and tags should only be removed by the person who installed them. If the person is unable to personally remove the lock and tag, verbal instructions can be given to remove the lock and tag. The instructions must include any specific measures required to return the machine to safe operating condition. If the person cannot be contacted, a supervisor and qualified technician (who has a thorough understanding of the machine) can remove the locks and tags. The locks and tags should only be removed when both the supervisor and technician agree that all systems are in order and there is no potential for injury.

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Removing Locks and Tags

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Safety Summary

CAUTION! Electrical hazard – risk of component damage. When powering up the machine, switch on the Q1M breaker switch before switching on the Q3M (if equipped) or Q2M breaker switches. Failure to do so can result in unnecessary wear on the components and lead to premature failure. 4.

Move the Q1M breaker switch to the ON position. This turns on power to the machine and Human Machine Interface (HMI).

NOTE: For machines shipped to European countries with the integrated mold heats option, the Q1M breaker controls power to the machine, HMI and mold heats. 5.

Move the Q2M breaker switch to the ON position. This turns on power to the integrated mold heats.

6.

If equipped, move the Q3M breaker switch to the ON position. This turns on power to motion control. 3

4

1

2 5

Figure 2-4

Breaker Switches (Typical)

1. Toggle Switch (If Equipped) 2. Rotary Switch (If Equipped) 3. Q2M Breaker Switch 4. Q1M Breaker Switch 5. Q3M Breaker Switch (If Equipped)

Removing Locks and Tags

7.

At the power manifold, turn each manual dump valve clockwise completely to allow the accumulator(s) to charge when the machine is started.

8.

Remove the lock and tag from the air regulator.

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1

HyPET Injection Molding Machine

2

3

4

Figure 2-5

Air Regulator With Lock and Tag (Typical)

1. Air Regulator 2. Shutoff Lever 3. Lock 4. Tag

9.

2.7

Turn the shutoff lever on the air regulator to turn on the air supply for the machine.

Personal Protective Equipment and Safety Equipment Personal injury can be avoided when personnel wear appropriate protective gear and use special safety equipment. The following describes the safety gear and equipment that should be used when working with the machine and any auxiliary equipment.

2.7.1

Personal Protective Equipment (PPE) Wear appropriate personal protective equipment when working on or near equipment. Standard personal protective equipment includes:

18

•

Safety glasses For protecting the eyes from flying objects/particles, heat, sparks, splash from molten material, and more

•

Face shield For protecting the entire face area from flying objects/particles, heat, sparks, splash from molten material, and more

•

Heat resistant gloves For protecting the hands from extreme heats

•

Hearing protection For protecting the ears from loud ambient noise

•

Safety shoes For protecting the feet from electrical shocks, crushing hazards, puncture hazards, splash from molten material, and more

•

Non-Melting Natural Fiber Pants and Long-Sleeve Shirt Personal Protective Equipment and Safety Equipment

Operator Manual

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Safety Summary

For protecting the body from potential splash from molten material

2.7.2

Safety Equipment Use appropriate safety equipment when working on or near equipment. Standard safety equipment includes:

2.8

•

Exhaust Fan For collecting potentially harmful plastic fumes

•

Purging Container For containing hot resin purged from the injection unit

•

Vacuum Cleaner For collecting spilled resin pellets and other debris that may create a falling hazard

•

Stairs and Ladders For ensuring safe access to areas of the machine

•

Danger Signs For warning other personnel to stand clear of a component or area of the machine

•

Locks and Tags For preventing the use of specific systems and components

•

Fire Extinguishers For the expedient suppression of small fires

•

Telescopic Mirror For safely inspecting hot runner nozzle tips from outside the mold area

Material Safety Data Sheet (MSDS) WARNING! Chemical hazard - Some of the chemicals used with Husky equipment are potentially hazardous and may cause injury and illness. Before storing, handling, or working with any chemical or hazardous material, thoroughly read and understand each applicable Material Safety Data Sheet (MSDS), use recommended personal protective equipment and follow the manufacturer’s instructions. The Material Safety Data Sheet (MSDS) is a technical document which indicates the potential health effects of a hazardous product. It contains safety guidelines to protect personnel, as well as information about use, storage, handling, and emergency procedures. Always refer to the applicable Material Safety Data Sheet before doing the following: • •

handling a chemical product disassembling any portion of Husky equipment that may result in exposure to a chemical product

Contact the material supplier to obtain a copy of the MSDS sheet. Safety Equipment

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2.9

HyPET Injection Molding Machine

Materials, Parts and Processing To prevent personal injury or damage to the equipment, make sure of the following: • • • • •

2.10

The equipment is only used for its intended purpose, as described in the manuals The operating temperatures do not exceed the specified permissible maximum value The maximum temperature set point is set below the ignition point of the material being processed Lubricants, oils, process materials and tools used on equipment meet Husky specifications Only authentic Husky parts are used

Safety Devices The machine is equipped with a number of safety devices designed to ensure the safety of the operator.

2.10.1 Warning Device The warning device alerts the operator and other personnel to conditions occurring in the machine. A standard warning device is installed on the clamp unit and features three warning lights: red, amber and blue. The red warning light activates when the machine stops due to an alarm condition. An optional audible horn also sounds to indicate the alarm condition. The blue warning light combined with a different optional audible horn indicates a pending warning on the software alarm screen. This feature gives an early warning to the operator that a cycle interruption will occur if not addressed. The amber warning light indicates an SPC-related alarm.

20

Materials, Parts and Processing

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Safety Summary

1

2

3 4

Figure 2-6

Warning Device (Typical)

1. Red Light 2. Amber Light 3. Blue Light 4. Horn

2.10.2 Emergency Stop Button Emergency stop (or E-stop) buttons are used to stop the machine in the event of an emergency. When pressed, all motors will stop, all heats will turn off, all solenoids will deenergize, and all hydraulic oil will return to the hydraulic tank. This machine is equipped with two emergency stop buttons. The buttons are located: • •

On the operator side below the Human Machine Interface (HMI) On the non-operator side inside the product handling area

1 2

Figure 2-7

Emergency Stop Buttons

1. Operator Side 2. Non-Operator Side

To use an emergency stop button:

Emergency Stop Button

1.

Push the emergency stop button to stop all machine motions and de-energize all systems.

2.

Correct the condition that prompted the use of the emergency stop button.

3.

Pull the button to reset it. 21

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HyPET Injection Molding Machine

1

Figure 2-8

2

Using the Emergency Stop Button

1. Pushing the Emergency Stop Button 2. Resetting the Emergency Stop Button

2.10.3 Product Handling Gate Reset Opening any product handling gate on the non-operator side of the machine will trigger an alarm and prevent the machine from operating. Press the Gate Reset button after closing the product handling gates to dismiss the alarm.

Figure 2-9

Gate Reset Button

2.10.4 Safety Gates and Doors The machine is equipped with safety gates and doors that prevent access to the mold, clamp and product handling areas. The gates and doors feature transparent panels for viewing the production area and a series of limit switches for each that trigger an alarm when the gates or doors are opened.

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Product Handling Gate Reset

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Safety Summary

1 2

3

Figure 2-10

Safety Gates (Typical)

1. Limit Switch (Typical) 2. Product Handling Gate 3. Front Gate

2.10.5 Mechanical Safety Device (If Equipped) The mechanical safety device inserts a pin into the clamp stroke column when the front safety gate is opened. This prevents unsafe movement of the moving platen while the mold area is accessible to personnel. 1

2

Figure 2-11

Mechanical Safety Device (Typical)

1. Mechanical Pin 2. Mold Stroke Column

2.10.6 CEN Valve The CEN valve prevents system hydraulic pressure from reaching the clamp, stroke, injection and ejection cylinders when either the safety gates or doors are opened. Limit switches monitor the position of the gates and activate the CEN valve when any gate is opened. Mechanical Safety Device (If Equipped)

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HyPET Injection Molding Machine

2.10.7 Automatic Dump Valve The automatic dump valve discharges all system pressure from the accumulator in a reasonably short period of time when the Pump Motor Off key is pressed on the HMI. This makes sure no hydraulic pressure is stored in the system when the machine is shut down.

2.10.8 Manual Dump Valve The manual dump valve is a backup safety device used to manually relieve hydraulic pressure in the system. Before servicing the hydraulic system, always turn the manual dump valve counter-clockwise to discharge any stored hydraulic pressure.

2

1

Figure 2-12

Manual Dump Valve (Typical)

1. Power Manifold Assembly 2. Manual Dump Valve

2.10.9 Purge Guard The purge guard protects the operator from molten resin that can be sprayed from the injection nozzle. Limit switches monitor the purge guard and trigger an alarm when the purge guard is opened.

WARNING! The machine is designed to keep the injection nozzle tip safely within the purge guard during operation and purging. Operating or purging the machine outside of this guarding is prohibited and can result in uncontained molten resin spray, causing serious injury or death.

24

Automatic Dump Valve

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Safety Summary

1

Figure 2-13

Purge Guard (Typical)

1. Purge Guard

2.10.10 Electrical Cabinet Door Interlocks and Override (UL only) NOTE: This safety device is available only on machines designed to Underwriters Laboratory (UL) standards. Each door on the electrical cabinet is equipped with an interlock switch that disables power to electrical components when one of the doors is opened.

Figure 2-14

Interlock Switch

For troubleshooting purposes, the interlock system can be overridden to maintain power while the doors are open. To override the interlock system, do the following: 1.

Insert the interlock override key into the key switch.

2.

Turn the key switch to the OFF position. The Door Interlock Off indicator push-button light will light up when the interlock system is disabled.

NOTE: The Door Interlock Off indicator push-button light can be pressed at any time to test the light. Replace the bulb immediately if it does not light up.

Electrical Cabinet Door Interlocks and Override (UL only)

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1

HyPET Injection Molding Machine

2

3

Figure 2-15

Electrical Cabinet Door Interlock

1. Door Interlock Off Push-Button Light 2. Door Interlock Key Switch 3. Electrical Cabinet

26

Electrical Cabinet Door Interlocks and Override (UL only)

Operator Manual

Chapter 3

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Specifications

Specifications This chapter details the pertinent technical specifications required by an operator.

NOTE: Husky reserves the right to change specifications without prior notice. Specification Hydraulic Oil Operating Temperature (Minimum to Maximum) Pneumatic Inlet Pressure

Value 47 to 53 °C (117 to 127 °F) 7.9 to 10.3 bar (115 to 150 psi)

Minimum Permissible Temperature for Plasticizing

182 °C (360 °F)

Maximum Permissible Temperature for Plasticizing

415 °C (779 °F)

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HyPET Injection Molding Machine

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Chapter 4

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Human Machine Interface (HMI)

Human Machine Interface (HMI) This chapter describes the basic features, functions and use of the Human Machine Interface (HMI). The HMI is used by the operator to control and monitor the machine.

IMPORTANT! Access to select features of the HMI is controlled through user access rights set by an administrator. Some screens and features described in this chapter may not be exactly as displayed on the HMI for your machine.

Figure 4-1

4.1

Human Machine Interface (HMI)

Access Rights Access to various HMI and machine functions is controlled through access rights assigned to individual users. Access rights are added, defined and removed by personnel with Administrator level profiles on the machine. An administrator can assign a user one or more rights depending on the user’s access requirements.

Access Rights

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Operator

Processor

Maintenance

Administrator

View operator screens

Slider

Rights

View Only

The user types and associated access rights are described as follows:



























Adjust sliders, plus limited access to certain machine functions Change operator setpoints



Change process setpoints



Calibrate machine



Switch languages and units







 

Manage machine users and rights Load mold setup parameters



Change machine





Change date and time formats





Set shifts



Install molds



 



NOTE: Some fields and buttons on the HMI screen will disappear or be greyed out if the user logged into the HMI has insufficient access rights.

4.2

Default User Name and Password It is the responsibility of the user with Administrator access to setup other users and assign them access rights based on their requirements. Until this is done, a default Operator profile can be used. The user name and password for the default Operator profile is as follows: Default User Name

operator

Default Password

123

IMPORTANT! The default user name and password for the default Operator profile should be changed immediately after commissioning the machine.

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Default User Name and Password

Operator Manual

4.3

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Human Machine Interface (HMI)

Logging On Access to the HMI and machine functions requires either a valid username and password, or a valid datakey. This section describes how to log on to the HMI using either method.

4.3.1

Logging On With a Datakey Two datakeys are provided by Husky with each machine. One key is for administrators only, while the other is for operators. Datakeys are used to save important user-specific information such as the user name, password, language setting and other configurations. If a datakey is available, insert it into the datakey port on the HMI. You will be automatically logged in to the HMI and all configuration settings saved on the datakey will be applied.

NOTE: The datakey must remain in the HMI to access machine functions. You will be logged out if the datakey is removed.

Figure 4-2

4.3.2

Datakey

Logging On With a Username and Password To login through the HMI, do the following: 1.

Touch the User Log On/Off button on the toolbar at the top of the screen to open the User Log On dialog box.

Figure 4-3

Logging On

User Log On/Off Button

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Figure 4-4

HyPET Injection Molding Machine

User Log On Dialog Box

1. User Name Field 2. Password Field 3. Domain Field 4. Accept Button 5. Exit Button

4.4

2.

Enter your username in the User Name field.

3.

Enter your password in the Password field

4.

If the machine is connected to a network, enter the network account in the Domain field. Otherwise, leave the field blank.

5.

Touch the Accept button to log on or touch the Exit button to cancel.

Logging Off To log off the HMI, touch the User Log On/Off button on the toolbar at the top of the screen. When a confirmation dialog box is displayed, press Yes to log off.

Figure 4-5

32

User Log On/Off Button

Logging Off

Operator Manual

4.5

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Human Machine Interface (HMI)

General Layout The front panel of the HMI consists of a touch-sensitive display screen and a series of control/function keys.

Figure 4-6

Human Machine Interface (HMI) Layout

1. Sidebar Function Keys 2. Cycle Mode Keys 3. Main Screen 4. Robot Function Keys 5. Pump Motor Keys 6. Control Keys 7. Screen Keys 8. Manual Function Keys

General Layout

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4.5.1

HyPET Injection Molding Machine

Sidebar Function Keys The sidebar function keys are used to monitor process values and control select machine functions during operation. The keys are positioned on both sides of the HMI display screen. The Sidebar Function Group key selects the group of sidebar functions and process values that are displayed. The Sidebar Function keys activate the individual sidebar functions within the group.

Figure 4-7

Sidebar Function Keys

1. Sidebar Function Group Key 2. Sidebar Function Group Icon 3. Sidebar Function Key 4. Sidebar Function Icon

The sidebar functions display either process values or enable functions. Process value icons display real-time values during operation about a specific component, such as high or low values for electrical components. Function icons activate specific functions, such as opening an air gate or closing the mold.

NOTE: Icons can be removed from or added to the group using the User Configuration screen. New user configured function groups can also be created and linked to a specific user profile for future use.

4.5.1.1 Accessing the Function Groups To display a function group, press the Sidebar Function Group key until the icon for the function group appears at the top of the sidebar. Alternatively, you can also scroll through the function groups until you find the Function Group Selector icon and then open the function group using the Sidebar Function keys. All related functions in a group are displayed next to the Sidebar Function keys below the function group icon.

34

Sidebar Function Keys

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Human Machine Interface (HMI)

4.5.1.2 Standard Sidebar Function Groups and Sidebar Icons The following is a list of the standard sidebar function groups and their associated icons. Sidebar Function Groups

Sidebar Functions

Machine

Ejector Auto

Screw Change

Screw Released

Screw Engaged

Injection Jog Forward

Injection Jog Back

Injection Monitoring

Injection Position

Injection Speed

Injection Pressure

Screw RPM

Air

Air Auto

Air Manual On

Standard Sidebar Function Groups and Sidebar Icons

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Sidebar Function Groups Product Handling

HyPET Injection Molding Machine

Sidebar Functions Tooling Plate In

Tooling Plate Out

CoolPik Horizontal

CoolPik Vertical

Tooling Plate Clear Parts

CoolPik Clear Parts

Conveyor Forward

Conveyor Back

CoolPik Part Transfer

Tooling Plate Cooling On

Tooling Plate Vacuum On

36

Standard Sidebar Function Groups and Sidebar Icons

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Human Machine Interface (HMI)

4.5.1.3 Function Group, Function and Process Value Icons Explained The following is a description of basic function group, function and process value icons used in the sidebars. Icon

Type Function Group

Function

Process Value

4.5.2

Description Each function group icon shares the following characteristics: 1.

A folder symbol

2.

A symbol representing the function group type

3.

A symbol representing the function type

4.

A number indicating the number of functions the group contains

Each function icon shares the following characteristics: 1.

A symbol that changes color when the function is active

2.

A symbol representing the function group type

3.

A symbol representing the function type

4.

The function number

Each process value icon shares the following characteristics: 1.

A process value symbol

2.

A symbol representing the function group type

3.

A numeric value that increases/decreases during machine operation

4.

The unit of measure for the process value

Cycle Mode Keys The Auto Cycle, Semi Cycle and Manual Cycle keys are used to select one of three available cycle modes for the machine. The cycle modes include automatic, semi-automatic and manual. Once automatic cycle or semi-auto cycle is selected, the Cycle Start key can be used to start the cycle.

NOTE: The Cycle Start key is not required to run the machine in manual cycle mode. Each key has an LED indicator in the top left corner that turns on when the cycle mode is selected.

Function Group, Function and Process Value Icons Explained

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Key

Name

HyPET Injection Molding Machine

Function

Cycle Start

Starts the machine cycle after a cycle mode is selected. The LED indicator will flash when the machine is ready to start.

Auto Cycle

Selects the automatic cycle mode.

NOTE: The LED indicator will flash if an alarm is triggered that must be cleared before the machine can cycle. Semi Cycle

Selects the semi-automatic cycle mode.

NOTE: The LED indicator will flash if an alarm is triggered that must be cleared before the machine can cycle. Manual Cycle

Selects the manual cycle mode.

NOTE: The LED indicator will flash if an alarm is triggered that must be cleared before the machine can cycle.

NOTE: On systems that have an integrated conveyor belt, the conveyor will run automatically when the Auto Cycle or Semi Cycle keys are pressed.

4.5.3

Robot Function Keys If the machine is equipped with a product handling robot, the Robot Home and Robot Enable keys can be used to activate and control the position of the robot. An LED indicator in the top left corner of the keys will turn on when the keys are active. Key

4.5.4

Name

Function

Robot Home

Returns the robot to the home position.

Robot Enable

Runs the robot during machine operation.

Pump Motor Keys The Pump Motor On and Pump Motor Off keys start and stop the pump motor. An LED indicator in the top left corner of the keys will turn on when the keys are active.

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Robot Function Keys

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Key

4.5.5

Name

Human Machine Interface (HMI)

Function

Pump Motor On

Turns on the pump motor.

Pump Motor Off

Turns off the pump motor.

Main Screen The main screen is a touch-sensitive display panel used to monitor machine functions and modify operating parameters. The touch-sensitive feature allows the user to touch parts of the screen to navigate between screens, change values, select options and more.

NOTE: Use the screen keys to change the displayed screen group. Refer to Section 4.5.6 for more information. 1

5

2 3

4

Figure 4-8

Main Screen

1. Message Bar 2. Toolbar 3. Tabs 4. Status Bar 5. Sidebar Function Icons

The screen area consists of the following parts: • • • • • Main Screen

Message Bar Toolbar Tabs Status Bar Sidebar Icons 39

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HyPET Injection Molding Machine

Message Bar The message bar displays the most current alarm message.

Toolbar The toolbar displays icons for common administrative and control functions, as well as the icon for the currently displayed screen group.

1

2

Figure 4-9

3

4

5

6

7

8

9

10

Toolbar

1. Current Screen Group 2. Language Selection 3. Screen Capture 4. Administrator 5. Calibration Selector 6. Machine Mode Selector 7. Alarm Horn Off 8. HMI Configuration 9. User Log On/Off 10. Online Documentation

Tabs When selected, each tab under the toolbar displays a screen belonging to the screen group.

Status Bar The status bar displays select machine status information for quick reference.

Figure 4-10

Status Bar

1. Current Cycle Mode 2. Machine Cycle Time 3. Oil Temperature 4. Current User Name 5. Current Date 6. Current Time

IMPORTANT! The thermometer in the oil temperature area is color coded as follows: • • •

Blue = Low Green = Normal Red = High

Sidebar Icons The sidebar icons represent machine functions or process values. Refer to Section 4.5.1 for more information.

40

Message Bar

Operator Manual

4.5.6

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Human Machine Interface (HMI)

Screen Keys The screen keys display the various screen groups on the HMI. There are nine main screen keys and three programmable screen keys (F10, F11 and F12) that may be used when necessary for optional auxiliary equipment. Each screen group can contain a series of screens, accessible by touching the tabs near the top of the main screen.

1

2

Figure 4-11

3

4

5

6

7

8

9

10

HMI Screen Keys

1. Alarms Key 2. Machine Key 3. Production Key 4. Clamp Key 5. Mold Function Key 6. Injection Key 7. Heats Key 8. Product Handling Key 9. SPC Key 10. Programmable Keys

NOTE: Some screen keys are for optional equipment or software. The screen key will be disabled if the related option is not installed on the machine.

4.5.7

Manual Function Keys The manual function keys activate specific functions when the machine is in manual cycle mode. Each key must be pressed and held to enable a function.

Figure 4-12

Manual Function Keys

1. Mold Open Key 2. Mold Close Key 3. Unclamp Key 4. Clamp Up Key 5. Ejector Back Key 6. Ejector Forward Key 7. Mold Cooling Key 8. Valve Gate Operation Key 9. Inject Key 10. Screw Rotate Key 11. Carriage Forward Key 12. Carriage Back Key

Each manual function key has an LED indicator that turns on when the function is enabled. The LED indicator will flash when the function is completed.

CAUTION! When using the Clamp Up key, make sure the mold is closed before applying tonnage.

Screen Keys

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Key

Name Opens the mold

Mold Close

Closes the mold

Unclamp

Disengages the clamp lock mechanism and retracts the clamp piston

Clamp Up

Extends the clamp piston and engages the clamp lock mechanism

Ejector Back

Retracts the ejector

Ejector Forward

Extends the ejector

Valve Gate Operation

Inject

Screw Rotate

Carriage Forward

Carriage Back

42

Function

Mold Open

Mold Cooling

[1]

HyPET Injection Molding Machine

Opens and closes the mold cooling water valve

Opens and closes the valve gates in the mold

Moves the injection piston and screw forward[1]

Rotates the plasticizing screw

Moves the injection carriage forward

Moves the injection carriage back

The optional nozzle shutoff valve will open if equipped.

Manual Function Keys

Operator Manual

4.5.8

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Human Machine Interface (HMI)

Control Keys Control keys are used to navigate through the HMI screens, escape dialog boxes and enter values. Key

Name

Function

Previous Screen

Opens the group of screens previous to the one currently displayed.

Next Screen

Opens the group of screens following the one currently displayed.

Escape

Enter

4.5.9

Exits dialog boxes.

Accepts changes or applies values entered using the numeric or alphanumeric touchpads

Common Screen Elements The following describes common tools and buttons that may be found on various screens.

4.5.9.1 Alphanumeric Touchpad The alphanumeric touchpad is a touch-sensitive keyboard for entering text. It displays whenever the user presses an alphanumeric input field, such as those found in the logon screen. The touchpad is used like a regular keyboard. Touch the numerals and characters as required and then touch the Enter key to apply the new text. The touchpad will close automatically once the value is entered. The touchpad also features buttons for entering common text or symbols. For example, the Husky button enters the word Husky in the display area.

Control Keys

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Figure 4-13

HyPET Injection Molding Machine

Alphanumeric Touchpad

1. Field Name 2. Display 3. Touch Sensitive Buttons 4. Enter Button 5. °C Button 6. Ç Button 7. Husky Button 8. Space Button 9. Clear Button 10. Cancel Button

4.5.9.2 Numeric Touchpad The numeric touchpad is a touch-sensitive keyboard for entering numeric values. It displays whenever the user presses a numeric input field. The touchpad is used like a regular keyboard. Touch the numbers as required and then touch the Enter key to apply the new value. The touchpad will close automatically once the value is entered. Alternatively, the numeric value can be increased or decreased incrementally using the Increase Value or Decrease Value buttons.

NOTE: On the screen behind the numeric touchpad, the background of the numeric input field being changed will turn yellow to indicate it is the field being edited.

44

Numeric Touchpad

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Figure 4-14

Human Machine Interface (HMI)

Numeric Touchpad

1. Field Name 2. Display 3. Clear Button 4. Touch Sensitive Button 5. Exit Button 6. Help Button 7. Enter Button 8. Increase Value Button 9. Value Range Indicator 10. Decrease Value Button

4.5.9.3 Common Buttons Many HMI screens contain similar buttons that can be used to perform specific functions. The following is a list of common buttons and their general functions. Button

Function The Exit button is used to close dialog boxes

The Information button is used to display additional information about a particular function or screen element The Expand View button is used on select screens to open a dialog box containing additional controls and values The More button opens a dialog box containing additional controls and values

The Recycle button is used to delete selected items

The Stop button is used to end a machine process or calibration function

The Help button is used to display the online documentation

Common Buttons

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Button

HyPET Injection Molding Machine

Function The Reset button is used to return all screen settings and values to their original, default values

The Accept button is used to confirm changes made to the HMI

The Cancel button is used to cancel changes made to the HMI

4.6

Setting the Machine Mode The Machine Mode Selector on the toolbar allows the user to set one of six modes for the machine. The modes allow the machine to operate with some functions enabled or disabled, depending on the type of operation being performed. Refer to Table 4-1 for more information. To select a function mode, do the following: 1.

Touch the Machine Mode Selector button on the toolbar to display the function mode icons. Refer to Figure 4-15.

1

2 3 4 5 6 7

Figure 4-15

Machine Mode Selector

1. Machine Mode Selector 2. Normal Cycle 3. Dry Cycle 4. Auto Purge Cycle 5. Mold Set Cycle 6. Screw Change Cycle 7. Unload All Pumps Cycle

2.

46

Select the desired mode.

Setting the Machine Mode

Operator Manual

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Table 4-1

Human Machine Interface (HMI)

Machine Cycle Modes

Mode Normal

Icon

Description Use Normal mode to operate the machine under normal conditions. The Semi Cycle, Auto Cycle and Manual Cycle keys are functional when this mode is selected.

Dry Cycle

Use Dry Cycle mode to disable the injection unit and cycle the clamp. The Semi Cycle, Auto Cycle and Manual Cycle keys are functional when this mode is selected.

Auto Purge

Use Auto Purge mode to disable the clamp unit and automatically purge the injection unit. The Semi Cycle, Auto Cycle and Manual Cycle keys are functional when this mode is selected.

Mold Set

Use Mold Set mode to operate the machine at reduced speeds and pressures during mold installation. Only the Manual Cycle key is functional when this mode is selected.

Screw Change

Use Screw Change mode to operate the extruder motor/gearbox at reduced speed when removing the plasticizing screw from the injection barrel. Only the Manual Cycle key is functional when this mode is selected.

Unload All Pumps

Use Unload All Pumps mode to direct flow from the hydraulic pumps to the hydraulic tank at low pressure. None of the cycle mode keys are functional when this mode is selected.

4.7

Generating On-Demand and Scheduled Reports The following procedures describe how to generate reports on-demand and at scheduled intervals. Reports provide important information about machine events and any changes that have been made to the HMI settings in a given time period. For more information about the types of reports that can be generated, refer to Section 4.7.1.

NOTE: Operator, Processor, Maintenance or Administrator level access rights are required to perform the following procedures.

4.7.1

Report Types The following report types can be generated through the Reports Selection screen:

Generating On-Demand and Scheduled Reports

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Report Types

4.7.2

HyPET Injection Molding Machine

Description

Cycle Interruption Report

Lists the number of cycle interruptions or machine state changes, the duration of each, the message displayed, and the response time.

Setpoint Change Report

Lists all setpoint changes including the original value, the new value, the unit of measure, and the reason (if applied).

Machine Events Report

Lists all types of machine events in chronological order including the type, the name of the component where the event originated, a description of the event, and the reason (if applied).

Generating On-Demand Reports To generate on-demand reports, do the following: 1.

On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

1 2 3 5

4

6

10 11

12

7 8 9

Figure 4-16

Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

2.

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In the On Demand Schedule area, select the check box for the desired report. Multiple reports can be selected at the same time. Refer to Section 4.7.1 for a description of each report type. Generating On-Demand Reports

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3.

In the Period area, select the time period to capture in the report.

4.

Touch the Generate Report button. A report for each report type selected is generated one after the other. To view the report(s), refer to Section 4.7.4. To print the report(s), refer to Section 4.7.5.

4.7.3

Enabling Scheduled Reports To enable scheduled reports, do the following: 1.

On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

1 2 3 5

4

6

10 11

12

7 8 9

Figure 4-17

Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

2.

In the On Schedule area, select the check box for the desired report. Multiple reports can be selected at the same time. Refer to Section 4.7.1 for a description of each report type.

3.

In the Schedule area, do the following: a. Select the check box for each day of the week the schedule(s) should be generated. b. Enter the time of day the schedule(s) should be generated.

4.

Select the Enable Scheduled Reporting check box. To view the report(s), refer to Section 4.7.4.

Enabling Scheduled Reports

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To print the report(s), refer to Section 4.7.5.

4.7.4

Viewing Reports To view on-demand or scheduled reports, do the following: 1.

On the HMI, press the Alarms key and touch the Report View tab to display the Report View screen. 1

2

3

4

5

Figure 4-18

Report View Screen

1. View On-Demand Report Button 2. View Scheduled Report Button 3. Print Button 4. Reporting Period Field 5. Report Window

4.7.5

2.

Select the type of report to view. Refer to Section 4.7.1 for a description of each report type.

3.

Touch either the View On-Demand Report or View Schedule Report buttons. The report is displayed in the report window and the date range is displayed Reporting Period field.

4.

To print the report after reviewing it, touch the Print button.

Printing Reports The following procedures describe how to print on-demand and scheduled reports.

NOTE: To print a report after viewing it, refer to Section 4.7.4 for more information.

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4.7.5.1 Printing On-Demand Reports To print an on-demand report, do the following: 1.

On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

1 2 3 5

4

6

10 11

12

7 8 9

Figure 4-19

Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

2.

Generate the on-demand report. Refer to Section 4.7.2 for more information.

3.

Touch the Print button.

4.7.5.2 Printing Scheduled Reports To print a scheduled report, do the following: 1.

Printing On-Demand Reports

On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

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1 2 3 5

4

6

10 11

12

7 8 9

Figure 4-20

Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

4.7.6

2.

Enable scheduled reports. Refer to Section 4.7.3 for more information.

3.

Select the Print Scheduled Reports check box. The report will print automatically at the scheduled time.

Saving Reports The following procedures describe how to save on-demand and scheduled reports.

4.7.6.1 Saving On-Demand Reports To save an on-demand report, do the following: 1.

52

On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

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1 2 3 5

4

6

10 11

12

7 8 9

Figure 4-21

Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

2.

Generate the on-demand report. Refer to Section 4.7.2 for more information.

3.

Touch the Save Report button.

4.7.6.2 Saving Scheduled Reports To save a scheduled report, do the following: 1.

Saving Scheduled Reports

On the HMI, press the Alarms key and touch the Reports Selection tab to display the Reports Selection screen.

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1 2 3 5

4

6

10 11

12

7 8 9

Figure 4-22

Reports Selection Screen

1. Cycle Interruption Report Check Box 2. Setpoint Change Report Check Box 3. Machine Events Report Check Box 4. Time Period Settings 5. End of Each Shift Check Box 6. Schedule Settings 7. Enable Scheduled Printing Check Box 8. Print Scheduled Reports Check Box 9. Save Scheduled Report(s) To Floppy Check Box 10. Generate Report Button 11. Print Report Button 12. Save Report Button

4.8

2.

Enable scheduled reports. Refer to Section 4.7.3 for more information.

3.

Select the Save Scheduled Report(s) to Floppy check box. The report will be saved automatically to a floppy diskette at the scheduled time.

Graphing Data Use graphs to monitor, analyze and save data collected during operation. Graphing tools are available for certain machine functions and allow the user to trace various data types. The following sections list the common graphing tools and how to generate graphs.

NOTE: Operator, Processor or Maintenance level access rights are required to perform the following procedures.

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Common Graphing Tools The following buttons and controls are available on select Graph screens in the HMI: Button

Function The Curve Selection button opens a dialog box that allows users to select which data types to plot The Graph Properties button opens a dialog box that allows users to control the display properties of the graph The Plot Configuration button opens a dialog box that allows users to control the display properties of individual curves The Start button starts plotting data on the graph

The Pause button pauses data plotting

The Stop button stops plotting data on the graph

The Move Left button scrolls the graph to the left

The Toggle Cursor button displays or hides the vertical cursor bar

The Move Right button scrolls the graph to the right

The Save Ideal Curves button saves the displayed curves as a set of ideal curves

The Ideal Curves button displays or hides a set of saved ideal curves

The Legend button displays or hides the color-coded legend for the graph

Common Graphing Tools

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Generating a Graph To generate a graph, do the following: 1.

For graphs that allow customization, do the following: • • •

Touch the Curve Selection button to display the Curve Selection dialog box. Select the data types to plot and touch the Exit button. Touch the Graph Properties button and modify the display properties of the graph as needed. Touch the Plot Configuration button and modify the display properties of each individual curve as needed.

NOTE: All curves are automatically scaled to display the complete curve. 2.

4.9

Touch the Start button to start plotting data.

Assigning Reasons When enabled by an administrator, operators are asked by the HMI to assign a reason whenever one of the following events occur: • • • •

A setpoint value is changed A check box or option button that affects a PLC process is selected or deselected A button is pressed that generates an event A combo box setting is modified

The reason is logged with the event for future analysis and troubleshooting. To assign a reason to an event, do the following:

NOTE: Operator or Processor level access rights are required to perform the following procedure. 1.

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In the Reason dialog box that appears after an event occurs, select the appropriate reason from the list to assign to the event.

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1

2 3 4

Figure 4-23

5 6

Reason Dialog Box

1. List of Reasons 2. No Comment Option 3. Last Comment Option 4. New Comment Field 5. Comment Field 6. Confirm Button

2.

In the Comments area, do one of the following: • • •

3.

Select the No Comment option to apply the reason without further details. Select the Last Comment option to apply the reason with the last comment entered. Select the New Comment option and enter a comment in the text field to apply with the reason.

Touch the Confirm button to close the dialog box.

4.10 Enabling/Disabling the Booster Cylinders (If Equipped) The booster cylinders provide additional force during production to remove preforms from the cores. Once the process has stabilized, the booster cylinders should be disabled. To enable or disable the booster cylinders, do the following: 1.

On the HMI, touch the Machine Mode Selector button on the toolbar and select Mold Set mode.

CAUTION! Mechanical hazard – risk of damage to the mold. If equipped, the boosters on the machine must be disabled before the core plate is installed. Failure to do so will cause damage to the mold. 2.

Press the Mold Function key and touch the Ejector Setup tab to display the Ejector Setup screen.

Enabling/Disabling the Booster Cylinders (If Equipped)

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1

Figure 4-24

Ejector Setup Screen

1. Booster Enable Check Box

3.

Under Booster, clear the Enable check box.

NOTE: If the Booster group is not available on the Ejector Setup screen, remove the solenoid cap from the booster. Refer to the electrical schematic for the machine to locate the booster.

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Enabling/Disabling the Booster Cylinders (If Equipped)

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Chapter 5

Starting the Machine

Starting the Machine This chapter describes the process for starting the injection molding machine.

NOTE: Some procedures in this chapter may refer to controls on the Human Machine Interface (HMI). For more information about the HMI, refer to Chapter 4–Human Machine Interface (HMI).

NOTE: HMI screens are representative and may not be identical to the ones on your machine.

IMPORTANT! The procedures contained in this chapter were written for a standard machine and do not take special options into consideration. When starting the machine, perform the following procedures in order: Step

Task Description

Reference

1

Inspect the machine

Section 5.1

2

Power up the machine

Section 5.2

3

Log on to the HMI

Section 5.3

4

Check the safety devices

Section 5.4

5

Check the hydraulic oil

Section 5.5

6

Check/reset the alarms

Section 5.6

7

Warm up the hydraulic oil

Section 5.7

8

Check the machine functions

Section 5.8

9

Check the product handling functions

Section 5.9

10

Check/enable the mold functions

Section 5.10

11

Cycle the machine and product handling unit

Section 5.11

12

Turn on the heats

Section 5.12

13

Prepare the process material feed

Section 5.13

14

Purge the injection unit[1]

Section 5.14

15

Clean the injection nozzle tip, purge guard and stationary platen

Section 5.15

16

Inspect the mold

Section 5.16

17

Precharge the hot runner[1]

Section 5.17

18

Produce test parts[1]

Section 5.18

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Step

Task Description

Reference

19

Enable SmartStart (optional)

Section 5.19

20

Enable SmartStop (optional)

Section 5.20

21

Start production[1]

Section 5.21

[1]

5.1

HyPET Injection Molding Machine

Not required if SmartStart is active.

Inspecting the Machine Before powering up the machine for production, inspect the machine and surrounding area to make sure it is ready for operation. During the inspection, do the following: • • • • • • • • • • • •

Make sure the floor is clean Make sure there are no fluid leaks Make sure all hoses and cables are connected and properly secured Make sure there are no missing parts Make sure all safety labels are installed Make sure there is no on-going maintenance Make sure all guards and gates are installed Make sure all personnel are clear of the machine Make sure all tools are clear of the machine Make sure all trip hazards are removed Make sure all emergency stop buttons are accessible Make sure the machine and auxiliary equipment (if equipped) is free of damage

Make sure all problems are corrected before powering up the machine.

5.2

Powering Up the Machine To power up the machine, do the following:

60

1.

If equipped, make sure the mold enclosure de-humidifier, compressed air and water chiller are enabled.

2.

Make sure the water chiller is adjusted to the correct operating temperature.

3.

If a direct feed system is equipped, make sure the dryer is loaded and adjusted to the proper operating temperature.

4.

Remove all locks and tags. Refer to Section 2.6.2 for more information.

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CAUTION! Electrical hazard – risk of component damage. When powering up the machine, switch on the Q1M breaker switch before switching on the Q3M (if equipped) or Q2M breaker switches. Failure to do so can result in unnecessary wear on the components and lead to premature failure. 5.

Move the Q1M breaker switch to the ON position. This turns on power to the machine and Human Machine Interface (HMI).

NOTE: For machines shipped to European countries with the integrated mold heats option, the Q1M breaker controls power to the machine, HMI and mold heats. 6.

Move the Q2M breaker switch to the ON position. This turns on power to the integrated mold heats.

7.

If equipped, move the Q3M breaker switch to the ON position. This turns on power to motion control. 3

4

1

2 5

Figure 5-1

Breaker Switches (Typical)

1. Toggle Switch (If Equipped) 2. Rotary Switch (If Equipped) 3. Q2M Breaker Switch 4. Q1M Breaker Switch 5. Q3M Breaker Switch (If Equipped)

Powering Up the Machine

8.

Wait for the patent screen to appear on the HMI.

9.

On the HMI, touch the Continue button.

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Figure 5-2

HyPET Injection Molding Machine

Patent Screen

1. Continue Button

10. Make sure the air supply is turned on. If necessary, turn the shutoff lever to the ON position.

Figure 5-3

Air Regulator (Typical)

1. Shutoff Lever

11. If necessary, adjust the air pressure by turning the adjustment knob. Refer to Chapter 3– Specifications for the required setting.

5.3

Logging On to the HMI Log on to the Human Machine Interface (HMI). Refer to Section 4.3 for more information.

NOTE: Access to the HMI requires a valid user name and password, or a datakey.

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Checking the Safety Devices Check the functionality of all safety devices. Refer to Section 7.4 for more information.

5.5

Checking the Hydraulic Oil Check the oil level in the hydraulic tank. Refer to Section 7.6 for more information.

5.6

Checking and Resetting the Alarms The machine will generate alarms during initial startup. Although some alarms will clear automatically as the startup process is completed, others restrict machine functions until they are resolved. To check for and reset alarms, do the following: 1.

On the HMI, press the Alarms key and touch the Alarms tab to display the Alarms screen.

2.

Touch the Clear Inactive Alarms button to clear all inactive alarms.

2

1

Figure 5-4

Alarms Screen

1. List of Active and Inactive Alarms 2. Clear Inactive Alarms Button

3.

Check the alarms list for alarms that automatically reset during startup. The following is a list of alarms that reset automatically:

Checking the Safety Devices

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Alarm

HyPET Injection Molding Machine

Resolution

Machine Heats Off

Deactivates after the machine heats are enabled.

Machine Heats Low Temperature Deviation

Deactivates after the machine heats are enabled and machine temperatures reach the setpoint values.

Oil Temperature Low

Deactivates after the oil temperature rises above 47 °C (117 °F).

Accumulator Charging in Progress

Deactivates a few seconds after the Pump Motor On key is pressed, when the accumulator(s) is fully charged.

4.

Check the alarms list for alarms that prevent machine operation and resolve the alarm. The following is a list of some alarms that prevent machine operation:

NOTE: The following list of alarms is not meant to be comprehensive. Possible Alarm

Resolution

Hydraulic Pump Motor Off

Press the Pump Motor On key to resolve the alarm.

Front Gate Open

Open and close the front gate to resolve the alarm.

NOTE: The limit switch must be tripped before the alarm can be reset. Rear Gate Open

Open and close the rear gate to resolve the alarm.

NOTE: The limit switch must be tripped before the alarm can be reset. Purge Guard Open

Close the purge guard to resolve the alarm.

Front Gate Opening Check Required

Open and close the front gate to resolve the alarm.

Rear Gate Opening Check Required Drop Bar Failure

NOTE: The limit switch must be tripped before the alarm can be reset. Open and close the rear gate to resolve the alarm.

NOTE: The limit switch must be tripped before the alarm can be reset. Open and close the front gate and make sure the air supply is turned on.

NOTE: The limit switch must be tripped before the alarm can be reset.

5.7

Warming the Hydraulic Oil The hydraulic oil must be at a suitable operating temperature before the machine can operate. Operating the machine when the hydraulic oil is cold can cause excessive wear or damage.

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To warm up the hydraulic oil in the machine, do the following: 1.

On the HMI, press the Manual Cycle key.

2.

Press the Pump Motor On key to start the pump motor.

3.

Check the oil temperature on the status bar and refer to Table 5-1 to determine any action required.

Figure 5-5

Status Bar

1. Hydraulic Oil Temperature

Table 5-1

Oil Temperature Conditions and Required Action

Temperature > 60 °C (140 °F)

58-60 °C (136-140 °F)

Oil Temperature Too High for Operation – Pump Off

Action 1.

Finish the cycle or stop the cycle if the time exceeds 5 minutes, whichever comes first.

2.

Press the Pump Motor Off key.

Oil Temperature Too High for Auto Cycle – Auto Cycle Will Be Disabled in 5 Minutes

Wait for the 5 minute timer to finish, then complete the cycle.

Oil Temperature Too High for Auto Cycle

Complete the cycle manually.

Oil Temperature Too High for Auto Cycle – Auto Cycle Will Be Disabled in 30 Minutes

Wait for the 30 minute timer to finish, then complete the cycle.

Oil Temperature Too High for Auto Cycle

Complete the cycle manually.

53-55 °C (127-130 °F)

High Oil Temperature

None

47-53 °C (116-127 °F)

None

None

45-47 °C (113-116 °F)

Oil Temperature Low

Allow the hydraulic oil to warm in Manual mode.

55-58 °C (130-136 °F)

Warming the Hydraulic Oil

Screen Message

5-45 °C (41-113 °F)

Oil Temperature Too Low – in Oil Warming

< 5 °C (40 °F)

Oil Temperature Too Low to Start Pump Motor

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HyPET Injection Molding Machine

Checking the Machine Functions To check the clamp and injection carriage functions, do the following: 1.

Make sure the pump motor is running and the Manual key is enabled.

2.

Make sure the machine mode is set to Mold Set.

3.

Press and hold the Mold Open key to open the mold.

4.

Press and hold the Mold Close key to close the mold.

NOTE: If the mold will not move, check and reset all mold related alarms. Refer to Section 5.6 for more information. 5.

Press and hold the Carriage Forward key to move the injection carriage forward.

6.

Press and hold the Carriage Back key to move the injection carriage back.

NOTE: If the injection carriage does not move, check and reset all injection function related alarms. Refer to Section 5.6 for more information. 7.

5.9

Check all hydraulic hoses, cylinders and manifolds for leaks.

Checking the Product Handling Functions To check the product handling functions, do the following: 1.

Make sure the pump motor is running and the Manual key is enabled.

2.

Make sure the machine mode is set to Mold Set.

3.

Make sure the mold is open enough for the tooling plate to enter the mold area by pressing and holding the Mold Open key as required.

4.

Display the Product Handling function group in the sidebar. Refer to Section 4.5.1 for more information.

5.

Press and hold the key next to the Tooling Plate In sidebar function icon. The tooling plate should enter the mold area.

6.

Press and hold the key next to the Tooling Plate Out sidebar function icon. The tooling plate should exit the mold area.

7.

Press and hold the key next to the CoolPik Horizontal sidebar function icon. The CoolPik should rotate until the CoolPik plate is parallel with the conveyor.

8.

Press and hold the key next to the CoolPik Vertical sidebar function icon. The CoolPik should rotate until the CoolPik plate is parallel with the tooling plate.

9.

Press the Conveyor Forward and Conveyor Backward keys on the sidebar to make sure the conveyor is operating correctly.

10. Press the key next to the Conveyor Backward sidebar function icon to turn off the conveyor.

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5.10 Checking/Enabling the Mold Related Functions To make sure the mold functions are enabled, do the following: 1.

On the HMI, touch the Machine Mode Selector on the toolbar and select Dry Cycle mode.

2.

Make sure the mold is open. If necessary, press and hold the Mold Open key to open the mold.

3.

Press and hold the Ejector Forward key to move the ejector forward.

4.

Press and hold the Ejector Back key to move the ejector back.

NOTE: If the ejector does not move, check the list of active alarms. Refer to Section 5.6 for more information. 5.

Display the Machine function group in the sidebar. Refer to Section 4.5.1 for more information.

6.

Press the Ejector Auto key on the sidebar to enable the ejectors. A green light in the corner of the icon indicates the function is enabled.

7.

Press and hold the Air Manual key on the sidebar. Air should blow through the mold.

8.

If necessary, press the Air Auto key on the sidebar to enable the compressed air supply for the mold. A green light in the corner of the icon indicates the function is enabled.

5.11 Cycling the Machine and Product Handling Unit To make sure the system functions as required, do the following: 1.

On the HMI, touch the Machine Mode Selector button on the toolbar and select Dry Cycle mode.

2.

Press the Robot Enable key to enable the product handling equipment.

3.

Press the Semi Auto Cycle key followed by the Cycle Start key to cycle the clamp.

4.

If necessary, adjust the clamp, mold functions and product handling settings.

5.12 Turning On the Heats The following procedures describe how to turn on the machine, mold and nozzle tip heats. Instructions on how to enable soft start and optimize the temperature control for mold heats are also included.

Checking/Enabling the Mold Related Functions

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5.12.1 Turning on the Machine, Mold and Nozzle Tip Heats (RS80/80) The following procedures describe how to turn on the machine, mold and nozzle tip heats for RS injection units. The following table lists the recommended time to allow the heats to reach operating temperature before production begins:

NOTE: For non-Husky molds and hot runners, always check the manufacturer’s documentation to determine how much time is required to pre-heat the mold or hot runner before production.

NOTE: Some resins may degrade when subjected to high heats for an extended period of time. Refer to the resin supplier’s documentation for specifications and restrictions.

NOTE: The time required for the heats to reach operating temperature varies depending on the mold or machine size.

[2]

Heats

Time Required to Reach Operating Temperature[2]

Machine

30 to 90 minutes

Mold

20 to 40 minutes

Nozzle Tips

6 minutes

Includes the additional soak time required after reaching operating temperature.

5.12.1.1 Turning on the Machine Heats To turn on the machine heats, do the following: 1.

68

Press the Heats key and touch the Machine tab to display the Machine screen.

Turning on the Machine, Mold and Nozzle Tip Heats (RS80/80)

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1 2 3

Figure 5-6

Machine Screen

1. Machine Heats Enable Check Box 2. Soft Start Check Box 3. Standby Check Box

2.

If necessary, enable Soft Start. Refer to Section 5.12.3 for more information.

CAUTION! Mechanical hazard – risk of resin degradation. Do not enable all heats at the same time. Some heats require more or less time than others to reach and soak sufficiently at operating temperature. Enabling either the machine, mold or nozzle tip heats for too long may cause the resin to overheat and degrade. 3.

Select the Machine Heats Enable check box at the appropriate time before production is scheduled to begin.

4.

Clear the Standby check box.

5.

If necessary, adjust the individual setpoint temperatures for the machine heats. Refer to Section 5.12.4 for more information.

5.12.1.2 Turning on the Mold Heats To turn on the mold heats, do the following:

Turning on the Mold Heats

1.

Make sure the machine is in Mold Set mode.

2.

If the mold is closed, on the HMI, press and hold the Mold Open key to open the mold.

3.

Press the Mold Function key and touch the Valve Gates tab to display the Valve Gates screen.

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1

Figure 5-7

Valve Gates Screen

1. Disable Valve Gate

4.

Make sure the Disable Valve Gate check box is clear.

CAUTION! Mechanical hazard – risk of damage to the mold. Turn mold cooling on before turning on the mold heats.

70

5.

Press the Mold Cooling key to start the mold cooling system.

6.

Press the Heats key and touch the Mold tab to display the Mold screen.

Turning on the Mold Heats

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1 2

Figure 5-8

3

Mold Screen

1. Hot Runner Enable Check Box 2. Soft Start Check Box 3. Standby Check Box

7.

If necessary, enable Soft Start. Refer to Section 5.12.3 for more information.

CAUTION! Mechanical hazard – risk of resin degradation. Do not enable all heats at the same time. Some heats require more or less time than others to reach and soak sufficiently at operating temperature. Enabling either the machine, mold or nozzle tip heats for too long may cause the resin to overheat and degrade. 8.

Select the Hot Runner Enable check box at the appropriate time before production is scheduled to begin.

9.

Clear the Standby check box.

10. If necessary, adjust the individual setpoint temperatures for the mold heats. Refer to Section 5.12.4 for more information.

5.12.1.3 Turning on the Nozzle Tip Heats To turn on the nozzle tip heats, do the following: 1.

Turning on the Nozzle Tip Heats

Touch the Nozzle Tips tab to display the Nozzle Tips screen.

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1 2

Figure 5-9

Nozzle Tips Screen

1. Nozzle Heats Enable Check Box 2. Soft Start Check Box

2.

If necessary, enable Soft Start. Refer to Section 5.12.3 for more information.

CAUTION! Mechanical hazard – risk of resin degradation. Do not enable all heats at the same time. Some heats require more or less time than others to reach and soak sufficiently at operating temperature. Enabling either the machine, mold or nozzle tip heats for too long may cause the resin to overheat and degrade. 3.

Select the Nozzle Heats Enable check box at the appropriate time before production is scheduled to begin.

4.

If necessary, adjust the individual setpoint temperatures for the nozzle tip heats. Refer to Section 5.12.4 for more information.

5.12.2 Turning on the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155) To turn on the machine, mold and nozzle tip heats, do the following:

72

1.

Make sure the machine is in Mold Set mode.

2.

If the mold is closed, on the HMI, press and hold the Mold Open key to open the mold.

3.

Press the Mold Function key and touch the Valve Gates tab to display the Valve Gates screen.

Turning on the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155)

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1

Figure 5-10

Valve Gates Screen

1. Disable Valve Gate

4.

Make sure the Disable Valve Gate check box is clear.

5.

Press the Heats key and touch the Setup tab to display the Setup screen.

1

3

2

4

3

2

5

Figure 5-11

Setup Screen

1. Machine Heats Enable Check Box 2. Soft Start Check Box 3. Standby Check Box 4. Hot Runner Enable Check Box 5. Nozzle Heats Enable Check Box

Turning on the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155)

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CAUTION! Risk of damage to the mold. Turn mold cooling on before turning on the mold heats. 6.

Press the Mold Cooling key to start the mold cooling system.

7.

If necessary, enable Soft Start for either the machine or mold heats. Refer to Section 5.12.3 for more information.

8.

If necessary, adjust the individual setpoint temperatures for the machine, mold and nozzle tip heats. Refer to Section 5.12.4 for more information.

CAUTION! Mechanical hazard – risk of resin degradation. Do not enable all heats at the same time. Some heats require more or less time than others to reach and soak sufficiently at operating temperature. Enabling either the machine, mold or nozzle tip heats for too long may cause the resin to overheat and degrade. 9.

Select the Machine Heats Enable, Hot Runner Enable and Nozzle Heats Enable check boxes at the appropriate time before production is scheduled to begin. The following table lists the recommended time to allow the heats to reach operating temperature before production begins:

NOTE: For non-Husky molds and hot runners, always check the manufacturer’s documentation to determine how much time is required to pre-heat the mold or hot runner before production.

NOTE: Some resins may degrade when subjected to high heats for an extended period of time. Refer to the resin supplier’s documentation for specifications and restrictions.

NOTE: The time required for the heats to reach operating temperature varies depending on the mold or machine size.

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Heats

Time Required to Reach Operating Temperature[3]

Machine

45 to 90 minutes

Mold

20 to 40 minutes

Nozzle Tips

6 minutes

Includes the additional soak time required after reaching operating temperature.

10. Clear the Standby check boxes under the Machine Heats and Mold Heats groups.

5.12.3 Enabling Soft Start Soft Start increases the temperature of the heats gradually to avoid surges and extend the life of the heats. Once the heats are at the defined temperature setpoint, Soft Start is automatically disabled and normal control is restored. To enable Soft Start for the machine, mold or nozzle tip heats, do the following:

NOTE: Soft Start is not available for nozzle tips on two-stage units. 1.

On the HMI, press the Heats key and touch either the Machine, Mold or Nozzle Tips tab to display the corresponding screen. 3 2

1

4

Figure 5-12

Machine, Mold and Nozzle Tips Screens (Screens for RS Injection Units Shown)

1. Machine Screen 2. Mold Screen 3. Nozzle Tips Screen 4. Global Change Button

2.

Enabling Soft Start

Touch the Global Change button. The Global Change dialog box appears.

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1 2 3 4

Figure 5-13

Global Change Dialog Box

1. Max. Duty Cycle Field 2. Soak Setpoint Field 3. Soak Deviation Band Field 4. Soak Time Field

3.

In the Soft Start area, do the following: a. Enter the percentage of power to use at startup in the Max. Duty Cycle field. b. Enter the temperature at which the heats should soak at in the Soak Setpoint field. The soak timer will begin when the temperature of the heats reaches this temperature. c. Enter the maximum number of degrees the soak temperature can deviate in the Soak Deviation Band field. d. Enter the amount of time the heats should soak for in the Soak Time field. The soak timer will stop when the timer reaches zero (0).

4.

Touch the Exit button to close the dialog box.

5.

For RS units, select the Soft Start check box to enable Soft Start. For Two-Stage Units, enable Soft Start by doing the following: a. Press the Heats key and touch the Setup tab to display the Setup screen.

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1

1

Figure 5-14

Setup Screen

1. Soft Start Check Box

b. In the Machine Heats or Mold Heats area, select the Soft Start check box to enable Soft Start.

Enabling Soft Start

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5.12.4 Configuring the Temperature Setpoints The following procedures describe how to configure the temperature setpoints for the machine, mold and nozzle tip heats. Temperature setpoints can be configured individually, or a global setpoint can be configured for all heats.

NOTE: For non-Husky molds and hot runners, always check the manufacturer’s documentation to determine the temperature requirements for the mold or hot runner. Procedure

Reference

Configuring individual temperature setpoints for machine or mold heat zones

Section 5.12.4.1

Configuring individual temperature setpoints for nozzle tip heat zones

Section 5.12.4.2

Configuring a global temperature setpoint for machine or mold heat zones

Section 5.12.4.3

Configuring a global temperature setpoint for nozzle tip heat zones

Section 5.12.4.4

5.12.4.1 Configuring an Individual Temperature Setpoint for a Machine or Mold Heat Zone To configure individual temperatures for each machine or mold heat zone, do the following: 1.

On the HMI, press the Heats key and touch either the Machine Heats or Mold Heats tab to display the appropriate screen. 2

1

3

Figure 5-15

Machine and Mold Screens

1. Machine Screen 2. Mold Screen 3. Heat Zone Setup Field

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IMPORTANT! For optimal temperature control in the mold, self-tuning should be enabled for the mold after a heat zone has been modified. Refer to the machine Service Manual for more information. 2.

Select a heat zone to configure and touch the Heat Zone Setup field. A dialog box opens.

1

3

2

4 5

Figure 5-16

Setup M/C Heats Dialog Box

1. High Deviation 2. Low Deviation 3. Setpoint Temperature Field 4. Auto Tune Enable Check Box 5. Enable Check Box

3.

To configure the heat zone, do the following: a. Touch the High Deviation field and type a suitable value. Refer to the mold Service Manual for more information. b. Touch the Low Deviation field and type a suitable value. Refer to the mold Service Manual for more information. c. Touch the Setpoint Temperature field and type the setpoint temperature. d. Make sure the Auto Tune Enable and Enable check boxes are selected.

5.12.4.2 Configuring Individual Temperature Setpoints for Nozzle Tip Heat Zones To configure individual temperatures for each nozzle tip heat zone, do the following: 1.

On the HMI, press the Heats key and touch the Nozzle Tips tab to display the Nozzle Tips screen.

Configuring Individual Temperature Setpoints for Nozzle Tip Heat Zones

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1

Figure 5-17

Nozzle Tips Screen

1. Setpoint Field

2.

Touch the setpoint field and type a suitable value.

5.12.4.3 Configuring a Global Temperature Setpoint for Machine or Mold Heat Zones To configure a global temperature setpoint for the machine or mold heat zones, do the following: 1.

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On the HMI, press the Heats key and touch either the Machine Heats or Mold Heats tab to display the appropriate screen.

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2

3

Figure 5-18

Machine Heats and Mold Heats Screens

1. Machine Heats Screen 2. Mold Heats Screen 3. Global Change Button

IMPORTANT! For optimal temperature control in the mold, self-tuning should be enabled for the mold after a heat zone has been modified. Refer to the machine Service Manual for more information. 2.

Touch the Global Change button. The Global Change dialog box appears.

1

4

2

5

3

6 7

8

Figure 5-19

Global Change Dialog Box

1. Setpoint Field 2. High Alarm Field 3. Low Alarm Field 4. Max. Duty Cycle Field 5. Soak Setpoint Field 6. Soak Deviation Point Field 7. Soak Time Field 8. Exit Button

3.

Touch each of the following fields and type a suitable value: • • • •

Setpoint field High Alarm field Low Alarm field Max. Duty Cycle field

Configuring a Global Temperature Setpoint for Machine or Mold Heat Zones

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Soak Setpoint field Soak Deviation Point field Soak Time field

Touch the Exit button to apply the changes.

5.12.4.4 Configuring a Global Temperature Setpoint for Nozzle Tip Heat Zones To configure a global temperature setpoint for the nozzle tip heat zones, do the following: 1.

On the HMI, press the Heats key and touch the Nozzle Tips tab to display the Nozzle Tips screen.

1

Figure 5-20

Nozzle Tips Screen

1. Global Change Button

2.

Touch the Global Change button. The Global Change dialog box appears.

1

2

Figure 5-21

Global Change Dialog Box

1. Setpoint Field 2. Exit Button

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3.

Touch the Setpoint field and type a suitable value.

4.

Touch the Exit button to apply the changes.

Starting the Machine

5.13 Preparing the Process Material Feed The machine can be fed process material through a hopper or a direct feed system. To prepare the process material, do the following:

WARNING! Slip, trip or fall hazard – risk of serious injury. Do not climb on the machine surfaces to access the hopper or direct feed system. Always use a safe platform. 1.

Fill the hopper with process material or connect the direct feed hose securely to the injection unit.

1 2

Figure 5-22

Process Material Feed Shutoff Systems

1. Hopper 2. Direct Feed System

WARNING! Burn hazard – risk of serious injury. Machine surfaces are hot. Wear personal protective equipment. 2.

If the machine is equipped with a direct feed system, open the feed lines to the machine.

3.

Open the process material feed manual or auto-shutoff. • •

4.

If a manual shutoff is equipped, refer to Section 5.13.1. If an auto-shutoff is equipped, refer to Section 5.13.2.

If the machine is equipped with an optional magnet drawer, open the drawer. Refer to Section 5.13.3 for more information.

Preparing the Process Material Feed

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5.13.1 Opening the Process Material Feed Manual Shutoff (If Equipped) To open the process material feed manual shutoff, do the following: 1.

Loosen the knob on the manual shutoff slider. 2 1

3

Figure 5-23

Opening the Process Material Feed Manual Shutoff (Typical)

1. Manual Shutoff Knob 2. Manual Shutoff Slider 3. Detent Pin

2.

Pull out the detent pin and push the slider forward until it is over the feed throat opening and the detent pin locks.

3.

Tighten the knob.

5.13.2 Opening the Process Material Feed Auto-Shutoff (If Equipped) To open the process material feed auto-shutoff, do the following: 1.

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On the HMI, press the Injection key and touch the Recovery tab to display the Recovery screen.

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1

Figure 5-24

Recovery Screen (Screen for Two-Stage Injection Units Shown)

1. Hopper Open Check Box

2.

Select the Hopper Open check box.

5.13.3 Opening the Magnet Drawer (If Equipped) Push the magnet drawer handle in all the way to open the process material feed.

Figure 5-25

Magnet Drawer (Typical)

1. Magnet Drawer Handle

Opening the Magnet Drawer (If Equipped)

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5.14 Purging the Injection Unit Before Production Purge the injection unit until the quality of the plasticized material is acceptable. For information about purging the injection unit, refer to Section 7.7. Purging the injection unit removes any dirt, obstructions or processed material that can affect production. The process is also used to transition from one color and/or type of resin to another.

IMPORTANT! This step is not required if SmartStart is used to startup the machine. For information about enabling and configuring SmartStart, refer to Section 5.19.

5.15 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen Clean the nozzle tip, stationary platen and purge guard. Refer to Section 7.3 for more information.

5.16 Inspecting the Mold To inspect the mold, do the following: 1.

Make sure the machine is in Mold Set mode.

2.

If the mold is closed, on the HMI, press and hold the Mold Open key to open the mold.

3.

Lock out and tag the machine. Refer to Section 2.6.1 for more information.

4.

Open the front gate.

WARNING! Explosion hazard – risk of serious injury. Molten material at high pressure can be present. Do not look directly at the nozzle opening. Use a telescopic mirror to inspect the nozzle opening and wear personal protective equipment consisting of a heatresistant coat, heat-resistant gloves and a full face shield over safety glasses to avoid injury.

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5.

Using a telescopic mirror, check the cavities on the cavity plate for drool.

6.

If drool is present, use brass tools to clean the cavities.

7.

Close the front gate.

8.

Remove all locks and tags. Refer to Section 2.6.2 for more information.

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5.17 Precharging the Hot Runner To precharge the hot runner with plastic, do the following: 1.

On the HMI, press the Mold Function key and touch the Valve Gates tab to display the Valve Gates screen.

1

Figure 5-26

Valve Gates Screen

1. Disable Valve Gate

2.

Make sure the Disable Valve Gate check box is selected.

IMPORTANT! This step is not required if SmartStart is used to startup the machine. Refer to Section 5.19 for information about enabling and configuring SmartStart. 3.

Precharging the Hot Runner

Press the Injection key and touch the Injection tab to display the Injection screen.

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1

Figure 5-27

Injection Screen

1. Fill Pressure Limit Field

4.

Record the value in the Fill Pressure Limit field for future reference.

5.

Set the Fill Pressure Limit value to 70 bar (1000 psi).

6.

Press the Clamp key and touch the Clamp tab to display the Clamp screen. Refer to the Actual Tonnage field to verify the tonnage.

1

Figure 5-28

Clamp Screen

1. Actual Tonnage Field

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7.

Press and hold the Mold Close key to close the mold.

8.

Press the Clamp Up key to apply tonnage to the mold. Refer to the actual Tonnage field to verify.

9.

Press the Injection key and touch the Recovery tab to display the Recovery screen.

10. Press and hold the Carriage Forward key until the nozzle tip is firmly seated against the mold sprue. Refer to the Forward Position field to verify.

1

Figure 5-29

Recovery Screen (Screen for Two-Stage Injection Units Shown)

1. Too Far Forward

11. Press and hold the Inject key to precharge the hot runner manifold(s) with resin. Release the Inject key once the piston slows down. 12. Press the Screw Rotate key to retract the screw. 13. Press the Unclamp key to release tonnage to the mold. 14. Press and hold the Mold Open key to open the mold.

5.18 Producing Test Parts To produce a set of test parts, do the following:

IMPORTANT! This step is not required if SmartStart is used to startup the machine. For information about enabling and configuring SmartStart, refer to Section 5.19.

Producing Test Parts

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1.

On the HMI, touch the Machine Mode Selector button on the toolbar and select Normal mode.

2.

Press the Robot Enable key to disable the product handling equipment. An LED indicator in the top left corner of the key will flash.

3.

Press the Manual Cycle key.

4.

Adjust all machine functions, as required.

5.

Display the Machine function group in the sidebar. Refer to Section 4.5.1 for more information.

6.

Press the Ejector Auto key on the sidebar to disable the ejectors.

7.

Press the Semi Cycle key followed by the Cycle Start key to cycle the machine once.

8.

Press the Manual Cycle key.

9.

Inspect the parts to verify the number and quality is satisfactory. If necessary, repeat step 7 to step 8 until the part quality meets the required specifications.

10. Press the Ejector Auto key on the sidebar to enable the ejectors. A green light in the corner of the icon indicates the function is enabled. 11. Press the Injection key and touch the Injection tab to display the Injection screen.

2

1

Figure 5-30

Injection Screen

1. Others Button 2. Fill Pressure Limit Field

12. Set the value in the Fill Pressure Limit field to the value recorded before precharging the hot runner. Refer to Section 5.17 for more information. 13. Press the Robot Enable key to enable the product handling equipment. 14. Press the Semi Cycle key followed by the Cycle Start key to cycle the machine once. Make sure all parts properly transfer to the product handling equipment. 15. Adjust all machine functions, as required. 90

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16. On the Injection screen, touch the Others button to open the Others dialog box.

1

Figure 5-31

Others Dialog Box

1. Cycle Compression Check Box

17. In the Others dialog box, select the Cycle Compression check box and then touch the Exit button.

5.19 Setting Up SmartStart (Optional) SmartStart is a semi-automatic tool that performs predetermined steps in the startup process with minimal operator assistance. The tool uses parameters defined on the SmartStart Setup screen during the startup sequence, and then switches to normal settings once the sequence is completed. This reduces overall startup time and possible errors during startup. To setup SmartStart, do the following: 1.

Setting Up SmartStart (Optional)

On the HMI, press the Production key and touch the SmartStart Setup tab to display the SmartStart Setup screen.

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1 2

12

3

13

4 5 6 7 8

9

10 11

Figure 5-32

SmartStart Setup Screen

1. Tonnage Field 2. Cooling Time Field 3. Fill Pressure Limit Field 4. Extruder Back Position Field 5. Ejector Forward Position Field 6. Ejector Forward Delay Field 7. Ejector Forward Dwell Field 8. Nozzle Tip Increase Field 9. Nozzle Tips Increase More Button 10. Nozzle Tips Warmup Field 11. Purge Cycles Field 12. Disengaged Field 13. Engaged Field

2.

Enter values in the following fields: Field

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Description

Tonnage

The clamp tonnage to be used. The light grey field displays the clamp tonnage defined on the Clamp screen.

Cooling Time

The time the mold halves remain together at the end of the hold phase. The light grey field displays the cooling time defined on the Clamp screen.

Fill Pressure Limit

The maximum allowable pressure that can be applied to the injection piston. The light grey field displays the fill pressure limit defined on the Clamp screen. The dark grey field displays the latched value from the previous cycle.

Extruder Back Position

The position the extruder stops at when it moves back. The light grey field displays the extruder back position defined on the Recovery screen.

Ejector Forward

The position the ejector stops at when it moves forward. The light grey field displays the ejector forward position defined on the Ejector Setup screen.

Ejector Forward Delay

The time between when the mold is fully open and the ejector starts to move forward.

Ejector Forward Dwell

The time the ejector remains in the forward position. The light grey field displays the normal dwell time defined on the Ejector Setup screen.

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Description

Nozzle Tips Increase

The percentage to manually increase the nozzle tip temperature by.

Nozzle Tips Warmup

The time allowed for the nozzle tips to warm to operating temperature. The light grey field displays the temperature setpoint defined on the Nozzle Tips screen.

Purge Cycles

The number of auto purge cycles to complete during startup. The light grey field displays the number of auto purge cycles that have been completed.

Disengaged

The number of semi cycles the machine should run with the product handling equipment disabled. The light grey field displays the number of completed cycles.

Engaged

The number of semi cycles the machine should run with the product handling equipment enabled. The light grey field displays the number of completed cycles.

3.

Touch the More button for the Nozzle Tips Increase field. The Nozzle Tips dialog box appears.

Figure 5-33 4.

Nozzle Tips Dialog Box

Select Nozzle Tip Increase to manually increase the nozzle tip temperature by the entered percentage value, or select Nozzle Tip Setpoint to increase the temperature to the value defined on the Nozzle Tips screen.

5.20 Setting Up SmartStop (Optional) SmartStop is a tool that automatically shuts down the machine when either a critical machine cycle fault occurs or any of the operator-selected events are completed. The operator can choose to automatically shut down the machine after producing an additional number of parts, after a production run is completed, or on a specific day and time.

Setting Up SmartStop (Optional)

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The SmartStop sequence eliminates the need for operator intervention, provides a safe way to shut down the machine in an emergency, reduces the risk of errors during shutdown, and makes subsequent startups smoother and easier.

IMPORTANT! The machine must be running in auto cycle mode for a minimum of 2 minutes before SmartStop activates. The following describes how to setup SmartStop to shut down the machine based on specific events.

IMPORTANT! The SmartStop sequence can be aborted by switching the machine to manual mode, or by clearing the appropriate Enable check box on the SmartStop Setup screen in the Production screen group.

5.20.1 Stopping on a Critical Machine Fault To setup SmartStop to shut down the machine when a critical machine fault occurs, do the following: 1.

On the HMI, press the Production key and touch the SmartStop Setup tab to display the SmartStop Setup screen.

2

1

Figure 5-34

SmartStop Setup Screen

1. Enable Check Box 2. Activate on Cycle Fault Field

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2.

In the Cycle Fault Option area, select Enable.

3.

In the Activate on Cycle Fault field, enter the amount of time that should elapse after a critical machine fault before the SmartStop sequence begins.

5.20.2 Stopping After Producing Extra Parts To setup SmartStop to shut down the machine after making an additional number of parts, do the following: 1.

On the HMI, press the Production key and touch the SmartStop Setup tab to display the SmartStop Setup screen.

1

3

2

Figure 5-35

SmartStop Setup Screen

1. Enable Check Box 2. After Extra Parts Option 3. After Extra Parts Field

2.

In the Operator Initiated Options area, select Enable.

3.

Select After Extra Parts.

4.

In the After Extra Parts field, enter the number of extra parts to produce before the SmartStop sequence begins.

5.20.3 Stopping After Completing Production To setup SmartStop to shut down the machine after a set number of parts have been produced, do the following: 1.

On the HMI, press the Production key and touch the SmartStop Setup tab to display the SmartStop Setup screen.

Stopping After Producing Extra Parts

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1 3

2

Figure 5-36

SmartStop Setup Screen

1. Enable Check Box 2. After Total Parts Option 3. After Total Parts Field

2.

In the Operator Initiated Options area, select Enable.

3.

Select After Total Parts.

4.

In the After Total Parts field, enter the total number of parts that must be produced before the SmartStop sequence begins.

5.20.4 Stopping on a Specific Day and Time To setup SmartStop to shut down the machine on a specific day and time, do the following: 1.

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On the HMI, press the Production key and touch the SmartStop Setup tab to display the SmartStop Setup screen.

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1

2 3

Figure 5-37

4

5

SmartStop Setup Screen

1. Enable Check Box 2. On Specified Day and Time Option 3. Day Drop-Down List Box 4. Hour Field 5. Minutes Field

2.

In the Operator Initiated Options area, select Enable.

3.

Select On Specified Day and Time.

4.

Select the day to activate SmartStop from the Day drop-down list box.

5.

Enter the hour in the Hour field.

6.

Enter the number of minutes in the Minutes field.

5.21 Starting Production The following describes how to start the production normally or automatically using SmartStart.

5.21.1 Starting Production Normally To start production normally, do the following:

Starting Production

1.

On the HMI, touch the Machine Mode Selector button on the toolbar and select Normal mode.

2.

Press the Auto Cycle key followed by the Cycle Start key to start production.

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5.21.2 Starting Production with SmartStart To start production using SmartStart, do the following: 1.

On the HMI, press the Production key and touch the SmartStop Setup tab to display the SmartStart Setup screen.

3 1

Figure 5-38

2

SmartStart Setup Screen

1. Start Button 2. Status Message Field 3. Stop Button

NOTE: SmartStart will automatically pause if an alarm occurs during the SmartStart sequence. The sequence will only resume once the alarm condition is cleared. Refer to the Status Message field for instructions.

NOTE: The SmartStart sequence can be aborted at any time by pressing the Stop button on the SmartStart Setup screen. SmartStart will stop once the current stage in the sequence is completed. 2.

Touch the Start button and follow all instructions displayed. When the SmartStart sequence is completed, the message SmartStart Completed will be displayed in the Status Message field.

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Chapter 6

Stopping the Machine

Stopping the Machine The machine is considered stopped when all motions stop and all stored energy is discharged. The machine is not considered stopped if one of these conditions is not met. For example, the machine is not considered stopped if the operator opens a safety gate. The safety gate interlocks will only stop machine motions, not de-energize the machine. This chapter describes three different ways to stop the machine: • • •

Stopping the machine in an emergency Pausing the machine Stopping the machine in a controlled manner

This chapter also discusses unexpected machine stoppages.

NOTE: Some procedures in this chapter may refer to controls on the Human Machine Interface (HMI). For more information about the HMI, refer to Chapter 4–Human Machine Interface (HMI).

6.1

Stopping the Machine in an Emergency The emergency stop button allows the operator to quickly stop the machine in an emergency. All machine motions will stop, the pump motor(s) will stop, and the hydraulic system pressure will be discharged when the emergency stop button is pressed.

CAUTION! Mechanical or electrical hazard – risk of damage to the machine. When powering down the machine in non-emergency situations, do not use the emergency stop buttons. Use the method described in Section 6.3 to avoid damaging the machine.

Stopping the Machine in an Emergency

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1 2

Figure 6-1

Emergency Stop Button Locations (Typical)

1. Operator Side Emergency Stop Button 2. Non-Operator Side Emergency Stop Button (Inside the Product Handling Area)

To stop the machine in an emergency, do the following: 1.

Push either the operator side or non-operator side emergency stop buttons to stop the machine.

1

Figure 6-2

2

Using an Emergency Stop Button

1. Push to Stop 2. Pull to Reset

6.2

2.

Correct all problems on the machine.

3.

Pull the emergency stop button out to restart the machine.

4.

Restart the machine as usual. Refer to Chapter 5–Starting the Machine for more information.

Pausing the Machine To pause the machine for a short period of time, do the following:

WARNING! Explosion hazard – risk of death or serious injury. Pressure can build up in a nozzle or feed throat area and cause some process material to explode. If the machine will be paused for longer than 90 seconds, purge the injection unit to prevent pressure build up. Refer to Section 7.7 for more information.

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1.

On the HMI, press the Semi-Auto Cycle key to activate the semi-auto cycle mode. The machine will complete one cycle and then stop.

2.

For two-stage injection units, do the following: a. Press the Heats key and touch the Setup tab to display the Setup screen.

1

2

3

Figure 6-3

Setup Screen

1. Standby Check Box for Machine Heats 2. Standby Check Box for Mold Heats 3. Nozzle Heats Enable Check Box

b. In the Machine Heats area, do the following: i.

Touch the field next to the Standby check box and type a suitable value.

ii. Select the Standby check box. c. In the Mold Heats area, do the following: i.

Touch the field next to the Standby check box and type a suitable value.

ii. Select the Standby check box. d. Clear the Nozzle Heats Enable check box to turn off the nozzle tip heats. 3.

For RS injection units, do the following: a. Press the Heats key and touch the Machine tab to display the Machine screen.

Pausing the Machine

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1

Figure 6-4

Machine Screen

1. Standby Check Box

b. In the Machine Heats area, do the following: i.

Touch the field next to the Standby check box and type a suitable value.

ii. Select the Standby check box. c. Touch the Mold tab to display the Mold screen.

1

Figure 6-5

Mold Screen

1. Standby Check Box

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Stopping the Machine

d. In the Mold Heats area, do the following: i.

Touch the field next to the Standby check box and type a suitable value.

ii. Select the Standby check box. e. Touch the Nozzle Tips tab to display the Nozzle Tips screen.

1 2

Figure 6-6

Mold Screen

1. Nozzle Heats Check Box 2. Soft Start Check Box

f.

6.3

Clear the Nozzle Heats Enable check box to turn off the nozzle tip heats.

Stopping the Machine in a Controlled Manner When stopping the machine at the end of a production cycle or for an extended period of time, perform the following procedures in order: Step

Task Description

Reference

1

Stop production[3]

Section 6.3.1

2

Shut off the process material feed

Section 6.3.2

3

Purge the injection unit

Section 6.3.3

4

Turn off all the heats

Section 6.3.4

5

Clean the nozzle tip, stationary platen and purge guard

Section 6.3.5

6

Empty the hopper/direct feed tube (optional)

Section 6.3.6

7

Clean the mold

Section 6.3.7

Stopping the Machine in a Controlled Manner

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Task Description

HyPET Injection Molding Machine

Reference

8

Turn off the mold cooling system (optional)

Section 6.3.8

9

Turn off the air supply (optional)

Section 6.3.9

10

Power down the machine (optional)

Section 6.3.10

[3]

Not required if SmartStop is active.

IMPORTANT! If SmartStop is active, some steps in the shut down sequence will be automatically completed by SmartStop. To disable SmartStop, press one of the emergency stop buttons.

IMPORTANT! The machine must be cycling for a minimum of 2 minutes before SmartStop activates.

6.3.1

Stopping Production To stop the production cycle, do the following: 1.

On the HMI, press the Semi-Auto Cycle key to take the machine out of automatic cycle mode. The machine will complete one complete cycle and then stop.

2.

Press the Manual Mode key.

3.

Press the Robot Home key.

NOTE: This step is not required if SmartStop is active.

6.3.2

Shutting Off the Process Material Feed To shut off the process material feed, do the following: 1.

104

If the machine is equipped with an optional magnet drawer, pull the handle out to shut off the process material feed.

Stopping Production

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Figure 6-7

Stopping the Machine

Magnet Drawer (Typical)

1. Magnet Drawer Handle

2.

Shut off the external process material supply to the hopper or direct feed tube.

3.

If the machine is equipped with an optional feed auto-shutoff system, do the following:

NOTE: If SmartStop is active, the hopper will be closed automatically during the SmartStop sequence. a. On the HMI, press the Injection key on the HMI and touch the Recovery tab to display the Recovery screen.

1

Figure 6-8

Recovery Screen (Screen for Two-Stage Injection Units Shown)

1. Hopper Open Check Box

b. Clear the Hopper Open check box.

Shutting Off the Process Material Feed

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WARNING! Burn hazard – risk of serious injury. Machine surfaces can be hot. Wear appropriate personal protective equipment. 4.

On the manual shutoff system, loosen the knob and pull the handle until the detent pin in the knob locks in the first position after the feed throat.

5.

Tighten the knob. 1

2

3

4

Figure 6-9

Closing the Process Material Feed Manual Shutoff (Typical)

1. Feed Throat Opening 2. Manual Shutoff Knob 3. Manual Shutoff Slider 4. Detent Pin

6.3.3

Purging the Injection Unit After Production Purge the injection unit until the plasticized material is depleted from the barrel. Refer to Section 7.7 for more information.

NOTE: If SmartStop is active and automatic purging is defined in the sequence, the injection unit will be purged automatically during the SmartStop sequence.

IMPORTANT! SmartStop will automatically abort if the injection unit is not empty after five purge cycles.

6.3.4

Turning Off All the Heats The following procedures describe how to turn off the machine, mold and nozzle tip heats.

NOTE: If SmartStop is active, the mold heats will be turned off automatically during the SmartStop sequence.

106

Purging the Injection Unit After Production

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Stopping the Machine

6.3.4.1 Turning Off the Machine, Mold and Nozzle Tip Heats (RS80/80) The following procedures describe how to turn off the machine, mold and nozzle tip heats for RS injection units.

6.3.4.1.1

Turning Off the Machine Heats To turn off the machine heats, do the following: 1.

On the HMI, press the Heats key and touch the Machine tab to display the Machine screen.

1 2 3

Figure 6-10

Machine Screen

1. Machine Heats Enable Check Box 2. Soft Start Enable Check Box 3. Standby Check Box

2.

6.3.4.1.2

Clear the Machine Heats Enable check box.

Turning Off the Mold Heats To turn off the mold heats, do the following: 1.

On the HMI, press the Heats key and touch the Mold tab to display the Mold screen.

Turning Off the Machine, Mold and Nozzle Tip Heats (RS80/80)

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1 2

Figure 6-11

3

Mold Screen

1. Hot Runner Enable Check Box 2. Soft Start Enable Check Box 3. Standby Check Box

CAUTION! Mechanical hazard – risk of damage to the mold. Leave the mold cooling system on until the mold cools to 37 °C (100 °F). 2.

6.3.4.1.3

Clear the Hot Runner Enable check box.

Turning Off the Nozzle Tip Heats To turn off the nozzle tip heats, do the following: 1.

108

On the HMI, press the Heats key and touch the Nozzle Tips tab to display the Nozzle Tips screen.

Turning Off the Nozzle Tip Heats

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Stopping the Machine

1 2

Figure 6-12

Nozzle Tips Screen

1. Nozzle Heats Enable Check Box 2. Soft Start Enable Check Box

2.

Clear the Nozzle Heats Enable check box.

6.3.4.2 Turning Off the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155) To turn off the machine, mold and nozzle tip heats, do the following: 1.

On the HMI, press the Heats key and touch the Setup tab to display the Setup screen.

Turning Off the Machine, Mold and Nozzle Tip Heats (P85/95E85 to P155/150E155)

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1 2 3

4 2 3

5

Figure 6-13

Setup Screen

1. Machine Heats Enable Check Box 2. Soft Start Enable Check Box 3. Standby Check Box 4. Hot Runner Enable Check Box 5. Nozzle Heats Enable Check Box

CAUTION! Mechanical hazard – risk of damage to the mold. Leave the mold cooling system on until the mold cools to 37 °C (100 °F). 2.

6.3.5

Clear the Machine Heats Enable, Hot Runner Enable and Nozzle Heats Enable check boxes.

Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen Clean the nozzle tip, stationary platen and purge guard. Refer to Section 7.3 for more information.

6.3.6

Emptying the Hopper/Direct Feed Tube (Optional) To empty the hopper or direct feed tube, do the following: 1.

110

If the machine is equipped with an external process material supply, check that the supply to the hopper or direct feed tube is shut off.

Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen

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Stopping the Machine

WARNING! Burn hazard – risk of serious injury. Machine surfaces and/or resin can be hot. To avoid serious burns, wear appropriate personal protective equipment. 2.

Place a container under the drain tube on the manual shutoff.

3.

Loosen the knob on the manual shutoff and pull the slider all the way until the detent pin in the knob locks in the last position at the discharge tube. Empty all process material through the discharge pipe. 1

2

3

4

Figure 6-14

Emptying the Hopper/Direct Feed Tube (Typical)

1. Feed Throat Opening 2. Manual Shutoff Knob 3. Manual Shutoff Slider 4. Detent Pin

4.

If the machine is equipped with an optional feed auto-shutoff system, do the following: a. On the HMI, press the Injection key on the HMI and touch the Recovery tab to display the Recovery screen.

Emptying the Hopper/Direct Feed Tube (Optional)

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1

Figure 6-15

Recovery Screen (Screen for Two-Stage Injection Units Shown)

1. Hopper Open Check Box

b. Select the Hopper Open check box. 5.

If the machine is equipped with an optional magnet drawer, push the handle in to open the process material field.

Figure 6-16

Magnet Drawer (Typical)

1. Magnet Drawer Handle

112

6.

After emptying the hopper or direct feed tube of all process material, push the slider until the detent pin in the knob locks at the first position before the feed throat. Make sure the feed throat opening is covered.

7.

Tighten the knob.

8.

If the machine is equipped with an optional magnet drawer, pull the handle to shut off the process material feed.

Emptying the Hopper/Direct Feed Tube (Optional)

Operator Manual

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Stopping the Machine

Cleaning the Mold Refer to the mold Service Manual for more information about cleaning the mold. After cleaning the mold, do the following:

6.3.8

1.

On the HMI, press the Pump Motor On key to turn on the pump motor.

2.

Press the Manual Cycle key.

3.

Touch the Machine Mode Selector button on the toolbar and select Mold Set mode.

4.

Press and hold the Mold Close key until there is a gap of approximately 5 mm (0.2 in) between the mold halves.

5.

Press the Pump Motor Off key to turn off the pump motor.

Turning Off Mold Cooling CAUTION! Mechanical hazard – risk of damage to the mold. Leave mold cooling on until the mold cools to 37 °C (100 °F). Press the Mold Cooling key on the HMI to turn off the mold cooling system.

6.3.9

Turning Off the Air Supply Turn off the air supply for the pneumatic system by turning the shut off lever on the air regulator clockwise.

Figure 6-17

Air Regulator

1. Shutoff Lever

Cleaning the Mold

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6.3.10 Powering Down the Machine To power down the machine, do the following: 1.

If equipped, move the Q3M breaker switch to the OFF position. This turns off power to motion control. 3

4

1

2 5

Figure 6-18

Breaker Switches (Typical)

1. Toggle Switch (If Equipped) 2. Rotary Switch (If Equipped) 3. Q2M Breaker Switch 4. Q1M Breaker Switch 5. Q3M Breaker Switch (If Equipped)

NOTE: For machines shipped to European countries with the integrated mold heats option, the Q1M breaker controls power to the machine, Human Machine Interface (HMI) and mold heats. 2.

Move the Q2M breaker switch to the OFF position. This turns off power to the integrated mold heats.

CAUTION! Electrical hazard – risk of component damage. When powering down the machine, switch off the Q3M (if equipped) and Q2M breaker switches before switching off the Q1M breaker switch. Failure to do so can result in unnecessary wear on components and lead to premature failure.

6.4

3.

Move the Q1M breaker switch to the OFF position. This turns off power to the machine and HMI.

4.

Perform all daily maintenance procedures. Refer to Chapter 7–Maintenance for more information.

Unexpected Machine Stoppage The machine can stop unexpectedly when certain alarms occur or if there is a power failure. If an alarm occurs, follow the instructions in the alarm message and then restart the machine as usual.

114

Powering Down the Machine

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Stopping the Machine

If there is a power failure, start the machine according to the instructions in Chapter 5– Starting the Machine.

NOTE: The Z-axis drive belt in the product handling unit must be thoroughly inspected if machine motion has been brought to a sudden stop. Refer to the machine Service Manual.

Unexpected Machine Stoppage

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Unexpected Machine Stoppage

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Chapter 7

Maintenance

Maintenance This chapter describes preventive and corrective maintenance tasks for the machine. Refer to Section 7.1 for the full maintenance schedule.

NOTE: Some procedures in this chapter may refer to controls on the Human Machine Interface (HMI). For more information about the HMI, refer to Chapter 4–Human Machine Interface (HMI).

WARNING! Chemical hazard - Some of the chemicals used with Husky equipment are potentially hazardous and may cause injury and illness. Before storing, handling, or working with any chemical or hazardous material, thoroughly read and understand each applicable Material Safety Data Sheet (MSDS), use recommended personal protective equipment and follow the manufacturer’s instructions.

IMPORTANT! The procedures contained in this chapter were written for a standard machine and do not take special options into consideration. Special options are documented, when available, in the Additional Information section on the documentation CD.

IMPORTANT! This chapter does not detail the maintenance tasks required for all auxiliary equipment. For more information about required maintenance, refer to the manufacturer’s documentation.

7.1

Maintenance Schedule Throughout the life of the machine, various systems and components will need to be inspected and serviced on a scheduled or non-scheduled basis. There are three types of maintenance procedures: • • •

Maintenance Schedule

Commissioning procedures are performed after the machine has been installed Preventive procedures are performed at scheduled intervals Corrective procedures are performed when required

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HyPET Injection Molding Machine

Commissioning The following maintenance procedures are to be performed only once after the initial startup of the machine. Interval

Reference

First Week

Check the accumulator precharge pressure

Service Manual

First Week

Check the quality of the hydraulic oil

Service Manual

First Two Weeks

Inspect the Z-axis drive belt

Service Manual

Replace the vacuum pump carbon dust separator filter cartridge

Service Manual

First Month or 500 Hours

7.1.2

Procedure

Preventive Maintenance The following maintenance procedures must be performed when indicated as part of the recommended preventive maintenance program for the machine. Interval Every Day

Every Week

Every 2 Weeks

118

Procedure

Reference

Drain the air regulator

Section 7.2

Clean the nozzle tip, stationary platen and purge guard

Section 7.3

Check all safety devices

Section 7.4

Clean the machine and HMI

Section 7.5

Check the oil level in the hydraulic tank

Section 7.6

Check the accumulator precharge pressure

Service Manual

Inspect and clean the hopper

Service Manual

Inspect and clean the magnet drawer

Service Manual

Inspect the conveyor belt

Service Manual

Inspect the hydraulic oil filter

Service Manual

Inspect the hydraulic tank breather cartridge

Service Manual

Inspect the oil recovery pockets

Service Manual

Inspect the Z-axis drive belt[1], [2]

Service Manual

Commissioning

Operator Manual

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Interval Every Month

Every 3 Months

Every 4 Months

Preventive Maintenance

Procedure

Maintenance

Reference

Check the hydraulic system pressure

Service Manual

Inspect all cooling water components

Service Manual

Inspect all electrical components

Service Manual

Inspect all hydraulic cylinders, valves and manifolds

Service Manual

Inspect all hydraulic hoses

Service Manual

Inspect all pneumatic hoses

Service Manual

Lubricate the clamp lock cylinder

Service Manual

Lubricate the mold stroke column guide bushings

Service Manual

Check the oil level in the extruder motor/gearbox

Service Manual

Clean the barrel head filter (P85/95E85 to P155/150E155)

Service Manual

Inspect the electric pump motor

Service Manual

Inspect the mold stroke column guide bushings

Service Manual

Inspect the nozzle shutoff assembly (if equipped)

Service Manual

Inspect the vacuum silencer

Service Manual

Inspect the Z-axis drive belt

Service Manual

Inspect the Z-axis linear bearings

Service Manual

Lubricate the injection unit (P85/95E85 to P155/150E155)

Service Manual

Lubricate the Z-axis linear bearings

Service Manual

Replace the coalescing filter on the oil recovery unit

Service Manual

Replace the clamp lock cylinder auto-lube cartridge

Service Manual

Lubricate the moving platen linear bearings

Service Manual

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Interval Every 6 Months

HyPET Injection Molding Machine

Procedure

Reference

Adjust the conveyor drive chain tension

Service Manual

Check the quality of the hydraulic oil[3]

Service Manual

Inspect the carriage cylinder bushings and pins

Service Manual

Inspect the vacuum pump carbon vanes

Service Manual

Lubricate the injection piston linear bearings

Service Manual

Lubricate the vacuum pump

Service Manual

Replace the oil retrieval filter element

Service Manual

Replace the hydraulic oil filter element

Service Manual

Replace the vacuum pump air inlet filter cartridges

Service Manual

Replace the vacuum pump carbon dust separator filter cartridge

Service Manual

Replace the vacuum silencer

Service Manual

Level the machine and adjust nozzle concentricity

Service Manual

Lubricate the electric pump motor bearings[4]

Service Manual

Replace the air regulator filter element

Service Manual

Replace the hydraulic tank breather cap

Service Manual

Replace the pressure filter element(s)

Service Manual

Torque the DC bus bar screws

Service Manual

Every 2 Years

Replace the oil in the extruder motor

Service Manual

Every 3 Years

Replace the hydraulic hoses

Service Manual

Every 3 Years

Replace the pneumatic hoses

Service Manual

Every 4 Years

Replace the Uninterruptible Power Supply (UPS) battery

Service Manual

Every Year

[1]

This check must be performed only if the Z-axis drive belt tension was greater than the required frequency in the last inspection.

7.1.3

[2]

Inspect the Z-axis drive belt two weeks after beginning production and then every three months.

[3]

This check must be performed semi-annually or every 4000 machine hours, whichever comes first.

[4]

Lubricate the pump motor bearings every 8000 hours of use or annually, whichever comes first.

Corrective Maintenance The following maintenance procedures are to be performed only when needed. Procedure

120

Reference

Adjusting the conveyor belt tension

Service Manual

Adjusting the conveyor drive chain tension

Service Manual Corrective Maintenance

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Procedure

Reference

Adjusting the Z-axis drive belt tension

Service Manual

Calibrating the machine

Service Manual

Calibrating the mold

Service Manual

Changing the high output plasticizing screw (RS65/65 to RS80/80)

Service Manual

Changing the plasticizing screw (P85/95E85 to P155/150E155)

Service Manual

Changing the plasticizing screw and check valve (RS45/45 to RS80/80)

Service Manual

Changing the resin color

Section 7.8

Checking all safety devices[5]

Section 7.4

Checking the oil recovery unit

Service Manual

Checking the vacuum pump motor rotation

Service Manual

Cleaning the heat exchangers

Service Manual

Clearing the feed throat

Service Manual

Discharging the accumulators

Service Manual

Disconnecting the machine cooling water supply

Service Manual

Installing a mold

Service Manual

Installing leveling mounts

Service Manual

Installing the clamp lock cylinder

Service Manual

Measuring servo valve data

Service Manual

Precharging the accumulators

Service Manual

Priming the clamp lock cylinder

Service Manual

Priming the clamp lock cylinder hydraulic hoses

Service Manual

Priming the cooling circuit

Service Manual

Priming the system and extruder pumps

Service Manual

Purging the injection unit

Corrective Maintenance

Maintenance

Section 7.7

Removing a mold

Service Manual

Removing air from the hydraulic system

Service Manual

Removing fixed guards with retentive bolts

Service Manual

Removing/installing the barrel (RS45/45)

Service Manual

Removing/installing the barrel (RS65/65 to RS80/80)

Service Manual

Removing/installing the plasticizing screw check valve

Service Manual

Removing the clamp lock cylinder

Service Manual

Removing water from the vacuum pump

Service Manual

Replacing a heater band

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Procedure Replacing the hydraulic breather cartridge

Service Manual

Replacing the hydraulic oil

Service Manual

Replacing the nozzle shutoff bushings (if equipped)

Service Manual

Replacing the plunger nozzle shutoff cartridge heaters (if equipped)

Service Manual

Replacing the servo valve seals

Service Manual

Replacing the vacuum pump carbon vanes

Service Manual

Replacing the water saver valve

Service Manual

Replacing the Z-axis drive belt

Service Manual

Replacing the Z-axis motor/gear reducer assembly

Service Manual

Tuning the mold heats

Service Manual

[5]

7.2

Reference

This check must be performed after upgrading software or performing maintenance on an interlock component.

Draining the Air Regulator To drain water from the air regulator, do the following:

CAUTION! Water condensation in the air regulator can cause rust damage to pneumatic components. Drain water from the regulator on a regular basis. 1.

Place a container under the air regulator.

1

Figure 7-1

Air Regulator (Typical)

1. Bleed Screw

122

Draining the Air Regulator

Operator Manual

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Maintenance

2.

Open the bleed screws on the underside of the air regulator to drain the water into the container.

3.

Tighten the bleed screws once all water has drained from the regulator.

Cleaning the Nozzle Tip, Stationary Platen and Purge Guard To clean the nozzle tip, stationary platen and purge guard, do the following:

WARNING! Explosion hazard – risk of serious injury. Molten material at high pressure can be present. Wear personal protective equipment and use a mirror to look into the nozzle opening.

WARNING! Burn hazard – risk of serious injury. Machine surfaces and molten process material can be hot. Wear personal protective equipment.

CAUTION! Risk of damage to the nozzle tip. Only use brass tools to remove process material buildup. 1.

On the HMI, press and hold the Carriage Back key to move the injection carriage away from the clamp.

2.

Open the purge guard.

3.

Use a brass tool to carefully remove all molten or solidified process material from the nozzle tip, stationary platen and purge guard.

4.

Close the purge guard.

5.

Press and hold the Carriage Forward key until the nozzle tip is firmly seated against the mold sprue.

WARNING! Burn hazard – risk of serious injury. Wear personal protective equipment when handling molten process material. 6.

After cleaning, discard the process material into a suitable metal container.

Cleaning the Nozzle Tip, Stationary Platen and Purge Guard

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HyPET Injection Molding Machine

Checking the Safety Devices The functionality of all safety devices on the machine must be checked before production begins. To confirm the functionality of these devices, perform the procedures in the following sections.

7.4.1

Checking the Emergency Stop Buttons The machine is equipped with emergency stop buttons located on the operator and nonoperator sides of the machine. To check the emergency stop buttons, do the following: 1.

On the HMI, press the Pump Motor On key to start the pump motor.

2.

Push one of the emergency stop buttons to shut down the machine.

1 2

Figure 7-2

Emergency Stop Buttons

1. Operator Side 2. Non-Operator Side

124

3.

Check that the pump motor stops and all machine motion stops when the button is pressed.

4.

Press the Alarms key and touch the Alarms tab to display the Alarms screen. The Emergency Stop alarm should be active (red).

Checking the Safety Devices

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Figure 7-3

7.4.2

Maintenance

Alarms Screen (Typical)

5.

Pull out the emergency stop button to reset the machine.

6.

Check that the Emergency Stop alarm is inactive (grey) in the Alarms screen.

7.

Repeat step 2 to step 6 to test the other emergency stop button.

Checking the Safety Gates The safety gate switches trigger an alarm when any safety gate is opened. The alarm will stop and prevent all machine motion to protect personnel from potential injuries. To check the functionality of the safety gate switches, do the following: 1.

Checking the Safety Gates

On the HMI, press the Alarms key and touch the Alarms tab to display the Alarms screen.

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Figure 7-4 2.

HyPET Injection Molding Machine

Alarms Screen (Typical)

Open the front gate and product handling gate.

1 2

3

Figure 7-5

Safety Gates (Typical)

1. Limit Switch (Typical) 2. Product Handling Gate 3. Front Gate

126

3.

Check the Alarms screen for active (red) Gate Open and Guard Open alarms.

4.

Close the front gate and product handling gate.

5.

Check the Alarms screen again. The Gate Open and Guard Open alarms should be inactive (grey).

Checking the Safety Gates

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Maintenance

IMPORTANT! Opening any product handling compartment gate triggers an alarm on the HMI, preventing the injection molding machine from operating. Press the gate reset button after closing the gates to dismiss the alarm. 6.

Press the Gate Reset button on the non-operator side of the machine.

Figure 7-6

7.4.3

Gate Reset Button (Typical)

Checking the Mechanical Safety Device (If Equipped) To check the mechanical safety device, do the following: 1.

Open the front gate.

2.

Check the pin is extended. 1

4

3

Figure 7-7

2

Mechanical Safety Device (Typical)

1. Pin 2. Mold Stroke Column 3. Solenoid Valve 4. Proximity Switch

3.

Check the indicator lights on the solenoid valve and proximity switch. The indicator lights should be off.

4.

Close the front gate.

5.

Check the pin is retracted.

Checking the Mechanical Safety Device (If Equipped)

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7.4.4

HyPET Injection Molding Machine

Checking the Automatic Dump Valve The automatic dump valve discharges all hydraulic system pressure from the accumulator when the Pump Motor Off key is pressed. To check the automatic dump valve, do the following: 1.

Remove the cap from the gauge port on the power manifold.

NOTE: Refer to the hydraulic schematic to determine the specific location of the gauge port.

7.4.5

2.

Attach a hydraulic pressure gauge with a quick disconnect fitting to the gauge port. The pressure gauge must be able to measure pressures up to 210 bar (3000 psi).

3.

On the HMI, press the Pump Motor On key to start the pump motor. Allow the pump motor to run for a minute to build up the temperature and pressure in the hydraulic system.

4.

Press the Pump Motor Off key to stop the pump motor.

5.

Check the pressure gauge to confirm the accumulator is fully discharged of any hydraulic pressure.

6.

Disconnect the pressure gauge and re-install the cap over the gauge port.

Checking the Purge Guard The purge guard protects the operator from molten resin spraying from the injection nozzle. To warn the operator when the purge guard has been opened during operation, a limit switch monitors the purge guard and activates an alarm when the guard is opened. To check the limit switch for the purge guard, do the following: 1.

128

On the HMI, press the Alarms key and touch the Alarms tab to display the Alarms screen.

Checking the Automatic Dump Valve

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Figure 7-8

7.4.6

Maintenance

Alarms Screen (Typical)

2.

Open the purge guard and check the Alarms screen. The Purge Guard Open alarm should be active (red).

3.

Close the purge guard and confirm the message is inactive (grey) in the Alarms screen.

Checking the CEN Valve The CEN valve prevents system hydraulic pressure from reaching the clamp, stroke, injection and ejection cylinders when either the safety gates or doors are opened. To check the functionality of the CEN valve, do the following: 1.

On the HMI, press the Pump Motor On key to start the pump motor.

2.

Touch the Machine Mode Selector button on the toolbar and select Mold Set mode.

CAUTION! If the clamp continues to move after the front gate is opened, press the emergency stop button. Contact Husky for more information. 3.

Press and hold the Mold Open key to retract the mold stroke column. As the mold stroke column is retracting, open the front gate. All clamp motion should stop immediately.

Checking the CEN Valve

4.

Close the front gate.

5.

Press the Pump Motor Off key to stop the pump motor.

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7.5

HyPET Injection Molding Machine

Cleaning the Machine and HMI To clean the machine and the Human Machine Interface (HMI) screen, do the following: 1.

Lock out and tag the machine. Refer to Section 2.6.1 for more information.

CAUTION! Mechanical hazard – risk of damage to the machine. Do not use solvents or abrasive materials to clean the machine or the HMI. Solvents and abrasive materials may cause corrosion or damage.

DANGER! Electrical hazard – risk of damage to the machine. Make sure water does not make contact with any electrical components during cleaning.

7.6

2.

Clean up any oil, dirt, grease or process material in and around the machine.

3.

Using a clean cloth and a cleaning solution made up of 70% denatured alcohol and 30% water, clean the HMI screen and membrane keys.

4.

Using a mild detergent, water and a lint-free cloth, clean all windows.

5.

Using a soft bristle brush and a vacuum cleaner, clean all pumps and motors accessible from outside the machine.

6.

Clean all ventilation intakes and cooling fans.

7.

Remove all locks and tags. Refer to Section 2.6.2 for more information.

Checking the Hydraulic Oil Level To check the hydraulic oil level, do the following: 1.

On the HMI, press the Pump Motor Off key to stop the pump motor.

2.

Check the hydraulic tank sight glass to determine the hydraulic oil level. The oil level should be between the one-half and three-quarter level. If the oil level is low, replenish the oil. Refer to the machine Service Manual.

130

Cleaning the Machine and HMI

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Figure 7-9

Maintenance

Hydraulic Tank Sight Glass (Typical)

1. Sight Glass

7.7

Purging the Injection Unit Purging the injection unit removes any dirt, obstructions or processed material that can affect production. The process is also used to transition from one color and/or type of resin to another. There are two methods for purging the injection unit: • •

7.7.1

Manual purging Auto purging

Manually Purging the Injection Unit To manually plasticize and purge material from the injection unit, do the following:

Purging the Injection Unit

1.

On the HMI, touch the Machine Mode Selector button on the toolbar and select Normal mode.

2.

Press the Manual Cycle key.

3.

Press the Heats key and touch the Machine tab to display the Machine screen.

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Figure 7-10

HyPET Injection Molding Machine

Machine Screen (Screen for Two-Stage Injection Units Shown)

4.

Make sure the injection unit is at operating temperature.

5.

Make sure the supply of process material is adequate for purging the barrel.

WARNING! Explosion hazard – risk of serious injury. Molten material at high pressure can be present. Wear personal protective equipment and clear the area of all non-essential personnel. Never purge the injection unit when the nozzle tip is outside the purge guard.

WARNING! The machine is designed to keep the injection nozzle tip safely within the purge guard during operation and purging. Operating or purging the machine outside of this guarding is prohibited and can result in uncontained molten resin spray, causing serious injury or death.

NOTE: The injection nozzle tip is in the purge position when the purge guard overlaps the barrel cover by at least 10 mm (0.4 in).

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6.

Make sure the carriage is in the purge position. If the carriage is not in the purge position, press and hold the Carriage Forward or Carriage Back key until the carriage stops automatically.

7.

Press the Injection key and touch the Injection tab to display the Injection screen.

Manually Purging the Injection Unit

Operator Manual

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Maintenance

1

Figure 7-11

Injection Screen

1. Injection Position Value

8.

Press and hold the Inject key to purge process material from the barrel. Release the Inject key when the Injection Position value reaches zero (0).

9.

Touch the Recovery tab to display the Recovery screen.

Figure 7-12

Recovery Screen (Screen for Two-Stage Injection Units Shown)

10. Press and hold the Screw Rotate key to retract the injection screw and plasticize the process material. Release the Screw Rotate key when the injection screw stops rotating. 11. Repeat step 7 to step 10 until the quality of plasticized material is acceptable. Manually Purging the Injection Unit

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HyPET Injection Molding Machine

WARNING! Burn hazard – risk of serious injury. Wear personal protective equipment when handling purged material. 12. After purging is completed and the purged material has cooled, empty the purge tray into a suitable metal container for disposal.

7.7.2

Auto Purging the Injection Unit To automatically plasticize and purge material from the injection unit, do the following: 1.

On the HMI, touch the Machine Mode Selector button on the toolbar and select Auto Purge mode. The injection carriage will automatically move into the purge zone.

2.

Press the Heats key and touch the Machine tab to display the Machine screen.

Figure 7-13

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Machine Screen

Auto Purging the Injection Unit

Operator Manual

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Figure 7-14

Maintenance

Machine Screen (Screen for Two-Stage Injection Units Shown)

3.

Make sure the injection unit is at operating temperature.

4.

Make sure the supply of process material is adequate for purging the injection unit.

5.

Press the Injection key and touch the Recovery tab to display the Recovery screen.

1

2

Figure 7-15

Recovery Screen (Screen for Two-Stage Injection Units Shown)

1. Hopper Open Check Box 2. Auto Purge Cycles Field

6.

Enter the number of purging cycles in the Auto Purge Cycles field.

7.

Make sure the Hopper Open check box is selected.

Auto Purging the Injection Unit

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8.

HyPET Injection Molding Machine

Press the Auto Cycle key followed by the Cycle Start key to start purging the injection unit automatically. Purging will stop automatically after the required number of purge cycles has been completed.

WARNING! Burn hazard – risk of serious injury. Wear personal protective equipment when handling purged material. 9.

7.8

After purging is completed and the purged material has cooled, empty the purge tray into a suitable metal container for disposal.

Changing the Resin Color To change the color of the resin, do the following: 1.

Lock out and tag the machine. Refer to Section 2.6.1 for more information.

2.

Remove all traces of the original resin from the material feed equipment.

3.

Depending on application restrictions, add one of the following to the material feed equipment to reduce the cleaning time required: • • •

Purge compound Natural (uncolored) resin New colored resin

4.

Remove all locks and tags. Refer to Section 2.6.2 for more information.

5.

Power up the machine and log on to the HMI. Refer to Section 5.2 for more information.

WARNING! Hot resin spray hazard – risk of death or serious injury. Molten resin under high pressure can suddenly release and spray out from the machine nozzle. Before purging the injection unit, clear the area of all non-essential personnel and wear personal protective equipment consisting of a heat-resistant coat, heat-resistant gloves and a full face shield over safety glasses.

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6.

Purge the injection unit until all traces of the old color are eliminated. Refer to Section 7.7 for more information.

7.

On the HMI, press the Injection key and touch the Injection tab to display the Injection screen.

Changing the Resin Color

Operator Manual

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Maintenance

2

1

3

Figure 7-16

Injection Screen

1. Injection Hold Time Setpoints 2. Injection Fill Speed Setpoints 3. Cooling Time

8.

Increase each Injection Fill Speed setpoint to its maximum value.

9.

Decrease each Injection Hold Time setpoint to its minimum value.

10. Decrease the Cooling Time to its minimum value. 11. Increase the temperature of the hot runner nozzle tips, manifolds and sprue by 20 to 30 °C (68 to 86 °F). Refer to Section 5.12.4 for more information. 12. Repeat step 3 to replenish the material feed equipment. 13. Produce a series of test parts until all traces of the old color are eliminated. 14. When the color change is complete, decrease the temperature of the nozzle tips, manifolds and sprue by 20 to 30 °C (68 to 86 °F). Refer to Section 5.12.4 for more information. 15. Return the Injection Hold Time setpoint, Injection Fill Speed setpoint and Cooling Time values back to their original values. 16. Fill the material feed equipment with the new resin.

Changing the Resin Color

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HyPET Injection Molding Machine

Changing the Resin Color