Wittmann Battenfeld VM R B8 Series Instruction Manual
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Wittmann Battenfeld VM R B8 Series Instruction Manual

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I N S T R U C T I O N
VM R B8 PRODUCT LINE
Read before using
the injection moulding machine
and keep nearby for reference.
M A N U A L

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Do you have a question about the Battenfeld VM R B8 Series and is the answer not in the manual?

Questions and answers

Dale
July 31, 2025

How to swing barrel out to pull screw

0
Mark Frazier
July 30, 2025

How do you get the clamp cylinder apart? I can't get the top of the cylinder threaded out of where the end threads in. We made a spanner wrench but still are unable to unscrew it what am I doing wrong?

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Summary of Contents for Wittmann Battenfeld VM R B8 Series

  • Page 1 I N S T R U C T I O N M A N U A L VM R B8 PRODUCT LINE Read before using the injection moulding machine and keep nearby for reference.
  • Page 2 TECHNOLOGY working for you. Wittmann Battenfeld GmbH Wr.Neustädter Straße 81 • 2542 Kottingbrunn • Österreich Tel. +43 (0) 2252 404-0 • Fax +43 (0) 2252 404-6102 info@wittmann-group.com www.wittmann-group.com/ DIN EN ISO 9001 Subject to technical changes without prior notice. We shall not accept any liability for damage caused by printing errors.
  • Page 3 instruction manual Production line xxx/xxxx/xxxxx R XXXX Machine model UNILOG B8 Control system type 137xxx-100 Machine number 2017 Year of manufacture VR2GBB8V00_0217 Numbe rof instruction manual 16.02.2017 Date of issue...
  • Page 5 1.........................Preface 1.1................................Introduction 1.2..............................Area of Applicability 1.3............................Explanation of symbols 1.4................................Copyright 1.5...............................Transfer Certifi cate 1.6............................Certifi cate of Conformity 2........................Safety 2.1..............................Safety regulations 2.1.1............................General information 2.1.2.................................Installation 2.1.3..........................Operation and maintenance 2.1.4......................Safety instructions affecting personnel 2.1.5...................... Safety regulations Hydraulics / pneumatics 2.1.6..................Safety regulations for the Modular Airmould System ®...
  • Page 6 3.5............................. Clamping unit VM R ................................. VM 40/ ... R752 ............................... VM 60/ ... R1040 ............................... VM 75/ ... R1040 ..............................VM 110/ ... R1280 ..............................VM 150/ ... R1280 ..............................VM 150/ ... R1520 ..............................VM 200/ ... R1520 ..............................
  • Page 7 4.12..............................Pneumatic system 4.12.1..............................Air supply unit 4.13............................Electrical equipment 5....................Mould mounting 5.1 ................................. Preparation 5.2..............................Mould mounting 5.3........................Quick-action mould mounting system 5.4................................Interfaces 5.5..........................Checking the safety devices 5.6............................ Test run and interlock test 6..................Structure and function 6.1............................... Clamping unit 6.1.1............................
  • Page 8 6.3.7..............................Pressure setting 6.3.8..............................Speed setting 6.3.9............................ Hydraulic oil preheating 6.3.10............................Hydraulic core puller 6.4................................Pneumatics 6.4.1............................Pneumatic core puller 6.4.2..............................Air supply unit 6.5................................Airmould 6.6................................Electrics 6.6.1..............................Electric drive 6.6.1.1......................... Three phase asynchronous motor 6.6.1.2........................Speed-controlled servo motor 6.6.2..............................Switch cabinet 6.7..............................
  • Page 9 8.6..............................Hydraulic system 8.6.1.................................Oil change 8.6.2................................ Deaeration 8.6.3............................Checking the oil level 8.6.4........................... Oil change Axial bearing 8.6.5..............................Hydraulic fi lter 8.6.6..........................Changing the fi lter element 8.6.7..............................Venting fi lter 8.6.8................................Leaks 8.6.9 ................................Oil cooler 8.7..............................Pressure vessel 8.7.1........................Checking the nitrogen pressure 8.7.2................Replenishing, reducing and testing the nitrogen pressure 8.7.3........................Checking the hydraulic pressure 8.8..............................Hose assemblies...
  • Page 10 VR2GBI2B800A Index - 6 0217TW...

  • Page 11: Liability / Warranty

    / or its plant components. Liability / Warranty Wittmann Battenfeld GmbH assumes no liability for property damage and human injury and/or environmental damage resulting from partial or full non-compliance with the operating manual. The warranty becomes invalid if unauthorised persons intervene in the equipment.

  • Page 12: Area Of Applicability

    Please observe the operating manual Knowledge of the contents of the technical documentation for the components is a precondition for protecting the employees from danger, preventing errors and for operating the components in a fl awless and safe manner. • Everyone entrusted with the transport, assembly, initial start-up, operation, maintenance or repair of the components must be knowledgeable of the operating manual.

  • Page 13: Explanation Of Symbols

    Explanation of symbols The Warning symbol is to be found with all work safety instructions in this operating manual where there is a hazard to the health and safety of persons. Follow these instructions and act in these cases with extreme care. Pass on all work safety instructions to other users. In addition to the instructions given in this operating manual the general health and safety regulations must be observed.

  • Page 14: Certificate Of Conformity

    The symbol for environmental hazard draws attention to environmental hazards, for instance in disposal of all sorts of materials. When carrying out repair and maintenance work the locally applicable laws and decrees have to be complied with. Copyright The copyright of this operating manual remains with Battenfeld GmbH. This operating manual is intended for assembly, operating and supervisory staff.
  • Page 15 Safety Safety regulations 2.1.1 General information Numerous safety devices on the machine contribute to safety and accident prevention. The proprietor is responsible for the effi cient operation of the safety devices. The machine has been designed and built to the currently applicable safety regulations in European Standard EN 201 and is safe to operate.

  • Page 16: Installation

    The installation of a mould-lifting crane from Wittmann Battenfeld GmbH may only be carried out by an authorised skilled technician. The crane may only be used for installing and removing moulds.

  • Page 17: Operation And Maintenance

    2.1.3 Operation and maintenance All work is in principal to be carried out with the machine being idle. The appropriate isolation procedures must be followed. Before starting work on the machine its drive and periphery equipment must be secured against accidental reconnection, e.g.
  • Page 18 2.1.4 Safety instructions affecting personnel All persons involved with the machine on the proprietor’s premises, whether for installation, dismantling, commissioning, operation, maintenance (inspection, service and repair) must fi rst read and understand the appropriate operating instructions, especially chapter "Safety". The proprietor is advised to have this confi...
  • Page 19 The proprietor is obliged to attach corresponding safety labels to moulds (not included in the scope of Wittmann Battenfeld GmbH of delivery) which are equipped with mould nozzles. These safety labels must instruct the operator to use the appropriate personal protective equipment for all work involving installation, dismantling, modifi...
  • Page 20 Looking directly into the nozzle area itself is not allowed. Use appropriate aids (e.g. a suitable mirror). In any work involving operation, installation, dismantling, modifi cation and maintenance, the following potential pinching or crushing hazards may arise: • Between the safety door and safety door frame on closing the clamping unit's safety door(s).
  • Page 21 The safety regulations for hydraulic hoses and hose assemblies to DIN 20066 and EN 201 are to be particularly carefully observed. Only hose assemblies with fi ttings that were either supplied or specifi ed by Wittmann Battenfeld GmbH should be implemented.
  • Page 22 (Type 2SN) whereas the outer layer must be permeable to nitrogen. The safety regulations according to DIN 20066 and EN 201 must also be followed. Only hose assemblies with fi ttings that were either supplied or specifi ed by Wittmann Battenfeld GmbH should be implemented.
  • Page 23 Hose assemblies must not be bent to a tighter bending radius than the minimum specifi ed by the manufacturer. Torque settings of the union nut must be reached at 1 to 1 1/2 turns of the union nut. To ensure the proper serviceability of hose assemblies they must be assembled according to DIN 20066.
  • Page 24 2.1.8 Safety regulations for electrics The electrical equipment on the machine is designed and built to the currently valid standards DIN EN 60204-1 and EN 61000-6-4, EN 61000-6-2 and is safe to operate. Hazards can, however, arise from the electrical system of this machine if it is improperly used by untrained personnel or is used for purposes for which it is not designed.
  • Page 25 It is absolutely necessary to meet the torque settings (according to the table) of the nozzle and the nozzle body. When installing a complete injection unit, only parts supplied or specifi ed by Wittmann Battenfeld GmbH may be used. When fi tting or removing the nozzle, screw or screw barrel it is essential to activate and use the machine without the guarding on the injection unit.
  • Page 26 Request safety specifi cation sheets according to ISO 11014 (safety specifi cation sheet for chemical products) for your products from your lubricant supplier. These cover: • Chemical and physical properties. • Protective measures, storage and handling. • Measures to be taken in the event of accidents and fi res. When disposing of electrical and electronic components, the local laws and regulations are to be observed.

  • Page 27: Technical Data

    Technical data The chapter "Technical data" contains all the technical data required for normal installation, commissioning and operation of the injection moulding machine. Miscellaneous Machine type / control see cover sheet Machine No. / year of construction see cover sheet Machine weight gross / nett see foundation and installation plan Main dimensions of the IMM...
  • Page 28 Pump output VM 40 - VM 270 Pump capacity (litres) VM 40/60 R752 VM 40/130 R752 VM 60/60 R1040 VM 60/130 R1040 VM 60/210 R1040 VM 60/350 R1040 VM 75/130 R1040 VM 75/210 R1040 VM 75/350 R1040 VM 75/525 R1040 VM 110/130 R1280 VM 110/210 R1280 VM 110/350 R1280...
  • Page 29 3.2.1 Pump output VM 60 - VM 200 Pump capacity (litres) VM 60/60 VM 60/130 VM 60/210 VM 60/350 VM 80/130 VM 80/210 VM 80/350 VM 80/525 VM 100/130 VM 100/210 VM 100/350 VM 100/525 VM 150/350 VM 150/525 VM 150/750 VM 150/1000 VM 200/525 VM 200/750...
  • Page 30 UNIFEED material feeder (option) Throughput At 6 bar (87 psi) air pressure, 100 % demand and a nominal 19 mm (0.75 inch) hose of which 4 m (13 ft) is vertical. Throughput PA (lb / h) kg / h HM_1044.WMF (562) (450) (338)
  • Page 31 Noise level Noise level dB / A HM_1045.WMF 70,5 69,5 68,5 (44) (58) (72) (87) (101) Pneumatic pressure (abs.) bar (psi) VMRGB0CD 1116TW Chapter 3 - 5...
  • Page 32 Injection fl ow outward with double 65,5 97,8 pump (Option) Barrel heating power Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 60/ ... R1040 Injection unit 60 H V 130 H V 210 H V...
  • Page 33 Barrel heating power 10,5 10,5 12,2 10,5 12,2 13,9 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 110/ ... R1280 Injection unit 130 H V 210 H V 350 H V 525 H V Screw diameter...
  • Page 34 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 150/ ... R1520 Injection unit 350 H V 525 H V 750 H V 1000 H V Screw diameter Screw stroke...
  • Page 35 12,2 13,9 17,5 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 200/ ... R1755 Injection unit 525 H V 750 H V 1000 H V Screw diameter Screw stroke Screw L/D ratio Calculated stroke volume Specifi...
  • Page 36 13,9 17,5 13,9 17,5 18,4 17,5 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard 3.4.1 Injection unit VM VM 60 Injection unit 60 H V 130 H V 210 H V 350 H V...
  • Page 37 Barrel heating power 10,5 10,5 12,2 10,5 12,2 13,9 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 100 Injection unit 130 H V 210 H V 350 H V 525 H V Screw diameter Screw stroke...
  • Page 38 12,2 13,9 12,2 13,9 17,5 13,9 17,5 18,4 Number of heating zones incl. nozzle 2) according to WITTMANN BATTENFELD standard VM 200 Injection unit 525 H V 750 H V 1000 H V Screw diameter Screw stroke Screw L/D ratio Calculated stroke volume Specifi...
  • Page 39 Clamping unit VM R VM 40/ ... R752 Clamping unit VM 40/... R752 Clamping force Diameter of rotary table Working height Min. mould mounting height Opening stroke / Opening force mm/kN 250/77 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Cooling circuits/temperature/nominal width -...
  • Page 40 VM 75/ ... R1040 Clamping unit VM 75/... R1040 Clamping force Diameter of rotary table 1.040 Working height Min. mould mounting height Opening stroke / Opening force mm/kN 250/132 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Cooling circuits/temperature/nominal width - n/°C/mm 2/120/9 –...
  • Page 41 VM 150/ ... R1280 Clamping unit VM 150/... R1280 Clamping force 1.500 Diameter of rotary table 1.280 Working height 1.065 Min. mould mounting height Opening stroke / Opening force mm/kN 300/277 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Cooling circuits/temperature/nominal width - n/°C/mm...
  • Page 42 VM 200/ ... R1520 Clamping unit VM 200/... R1520 Clamping force 2.000 Diameter of rotary table 1.520 Working height 1.065 Min. mould mounting height Opening stroke / Opening force mm/kN 300/327 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Cooling circuits/temperature/nominal width - n/°C/mm...
  • Page 43 VM 270/ ... R1755 Clamping unit VM 270/... R1755 Clamping force 2.700 Diameter of rotary table 1.755 Working height 1.325 Min. mould mounting height Opening stroke / Opening force mm/kN 400/445 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Cooling circuits/temperature/nominal width - n/°C/mm...
  • Page 44 VM 80/ ... Clamping unit VM 80/... Clamping force Distance between tiebars mm x mm 420 x 370 Working height 1.145 Min. mould mounting height Opening stroke / Opening force mm/kN 375/158 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Dry cycle time...
  • Page 45 VM 200/ ... Clamping unit VM 200/... Clamping force 2.000 Distance between tiebars mm x mm 620 x 570 Working height 1.295 Min. mould mounting height Opening stroke / Opening force mm/kN 450/370 Max. platen distance Ejector stroke / Ejector force mm/kN 150/27,5 Dry cycle time...
  • Page 46 Maximum mould weights The required dimensional accuracy of the mouldings, the loading on the mould and the mould's function especially with complex tooling (multi-plate tools, side actions) are heavily dependent upon the parallelism of the machine platens. The degree of parallelism required by EUROMAP 9 will be achieved if the following mould weights are not exceeded: http://www.euromap.org/fi...
  • Page 47 Operation of the feed zone The feed zone is water-cooled. Set the temperature via the monitor to such a value that the plastic granulate does not become melted in the feed zone of the screw. Due to the steel material of the feed zone it is also possible to use metal fi ttings in addition to the plastic fi...
  • Page 48 VMRGB0CD Chapter 3 - 22 1116TW...
  • Page 49 3.10 Weights of screws and barrels Load requirements for screw barrel including screw when performing a screw and barrel change. Injection unit Screw diameter Weight [mm] [inch] [kg] [lbs] 0,55 0,71 0,87 0,98 1,18 60 - 1330 1,38 1,57 1,77 1,97 2,17 2,56...
  • Page 50 Load requirements for the screw when performing a screw change. Injection unit Screw diameter Weight [mm] [inch] [kg] [lbs] 2,17 2250 2,56 2,95 2,56 3400 2,95 3,35 2,95 5100 3,35 3,74 3,74 8800 4,13 4,72 4,72 13800 5,31 5,91 1103 4,72 5,31 19000...
  • Page 51 3.12 Tightening torque for bolts The torque settings are listed in the spare parts list together with the screws showing different settings. These settings must absolutely be kept. The torques are based on a frictional factor of 0.125 (μmtotal) for untreated, Molykote lubricated and cadmium electroplated surfaces, but not for slightly oiled ones.
  • Page 52 3.13 Torque settings for the fastening screws of the screw barrel head These torque settings are valid for socket head cap screws (1) for fastening the nozzle head (2). Further information on tensile strengths etc. can be found in the spare parts lists. The torques are based on a frictional factor of 0.125 (μmtotal) for untreated, Molykote lubricated and cadmium electroplated surfaces, but not for slightly oiled ones.

  • Page 53: Transport - Installation

    All the keys etc. for the switch cabinet, guarding etc. are to be found attached to the main switch. We would recommend installation of the machine to be carried out by personnel of the Wittmann Battenfeld GmbH. We can accept no responsibility for damage resulting from improper handling.

  • Page 54: Packing Instructions

    If there is no level surface, a foundation must be built for the machine according to the "Foundation and Installation Plan", see "Technical Data" chapter, to provide a level base. If transport to the fi nal location is impossible with cranes, the machine must be supported under its entire base for moving across the fl...

  • Page 55: Transporting The Machine

    Sea transport in seaworthy box • Preservation of bare parts with a corrosion inhibitor. • Tightly seal machine in plastic sheet (include moisture absorber). • Close box with steel bands and provide lifting fi xtures. • Mark the centres of gravity. Transporting the machine This machine is equipped with a transport monitoring system.
  • Page 56 For installation, dismantling, modifi cation, adaptation, and maintenance, work parts, components or the entire machine have to be secured and carefully attached to the lifting gear so as to prevent any dangers from arising. Only use appropriate lifting gear in proper working order with suffi...

  • Page 57: Machine Weight

    4.2.1 Machine weight Machine weight (without oil) VM R Machine weight (without oil) VM VM 40/60 R752 4300 9500 VM 60/60 3750 8300 VM 40/130 R752 4400 9700 VM 60/130 3800 8400 VM 60/60 R1040 5900 13000 VM 60/210 3850 8500 VM 60/130 R1040 6000...

  • Page 58: Transport Safety Devices

    4.2.2 Transport safety devices VMR transport safety device: The transportation devices (pos1, 3x) must be removed before commissioning and must be reattached without fail before moving the IMM again! VM transportation device: The transportation devices (pos1, 2x) must be removed before commissioning and must be reattached without fail before moving the IMM again! VR2GB0DB800A Chapter 4 - 6...
  • Page 59 Erecting the machine The machine may only be installed in a dry, dust-free environment above freezing point. The machine body completely rests on the wedge elements. Adjustment of the oscillating elements Adjustment is made by means of the hexagon bolt. A hexagonal nut (2) is used as a lock nut to fi...
  • Page 60 CAUTION Do NOT protect the spindle with a preservative agent or remove the corrosion protection! If corrosion protection is required, use the prescribed operation grease. These cleaning fl uids are considered hazardous to health and are fl ammable. Follow the manufacturers’...
  • Page 61 VMR clamping unit: Mould mounting surfaces Tiebars VM clamping unit: Mould mounting surfaces Tiebars VR2GB0DB800A 0217TW Chapter 4 - 9...

  • Page 62: Levelling The Machine

    Levelling the machine The injection moulding machine may only be installed in a dry, dust-free environment above freezing point. The machine body must completely rest on the levelling mount or the wedge elements. Levelling the VMR machine: A machine spirit level with an accuracy of 0.1 mm / m (0.004 inch / 3.281 ft) are essential for levelling the injection moulding machine.

  • Page 63: Hydraulic System

    For the position of the oil fi ller neck, refer to chapter Maintenance 8.5. Only use prefi ltered hydraulic oil of cleanliness class 17/15/12 acc. to ISO 4406! The WITTMANN BATTENFELD GmbH recommends HLP 32 (see chapter 8.4 "Hydraulic oil and lubricant table")
  • Page 64 CAUTION Test the hydraulic oil for the possible ingress of water! Never switch the machine on without hydraulic oil. Even the shortest period of running will damage hydraulic equipment! When fi lling for the fi rst time the following sequence must be followed without fail: •...
  • Page 65 4.10.2 Commissioning of the hydraulic pump • Activation of the pump rinsing program for pump systems CAUTION Before switching on the hydraulic pump the hydraulic motor's direction of rotation should be checked! • Start the machine • If there is air present in the pump system, e.g. due to a pump or oil change, activate this program to eliminate the air from the system •...

  • Page 66: Pressure Vessel

    4.10.3 Bleeding After fi lling the hydraulic tank air must be bled from the hydraulic system. • Connect power; see "Electrical equipment" paragraph • Connect cooling water; see "Water system" paragraph. • Press the "Hydraulic start" key to switch on the hydraulics •...
  • Page 67 Neither welding nor soldering nor any mechanical processing may be performed on the pressure vessels. Improper repairs can cause severe accidents and may only be carried out by authorised customer service personnel. Replenishing, reducing and checking nitrogen pressure CAUTION The nitrogen pressure changes temperature dependently. For this reason, inspections should always be carried out under equal temperature conditions.
  • Page 68 Check whether the venting valve of the fi ller unit is closed. Screw the hose assembly’s connecting piece to the nitrogen bottle. Slightly open the shut-off valve of the nitrogen bottle and have the nitrogen slowly fl owing into the pressure vessel (for the fi lling pressure please refer to the hydraulic plan or the respective label).

  • Page 69: Water System

    4.11 Water system CAUTION When installing water pipework note the corrosion stability of metallic materials against water in accordance with DIN 50930! 4.11.1 Water quality If there are deviations from the following guidelines, please contact our technical customer service or one of our subsidiaries. The addresses can be found in the "Customer service" chapter.

  • Page 70: Cooling Water Connection

    4.11.2 Cooling water connection If the cooling system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! The cooling system for the machine can also be run as a closed cooling system. The required nominal diameters of the hoses are quoted in the chapter "Technical data".
  • Page 71 Burning hazard if touched! Wear suitable PPE with water temperatures above 50 °C (122 °F)! Injury hazard to operating and other personnel and possible damage to cooling water fl ow governor if used at improper temperatures and pressures! The cooling water pressure must be set for different temperatures according to the following table: Temperature max.

  • Page 72: Oil Cooling

    4.11.4 Oil cooling The hydraulic oil is cooled in a heat exchanger. In which the cooling water is passed through a cooling coil surrounded by the hydraulic oil. A solenoid valve regulates the water fl ow. By allowing or interrupting the cooling water supply it achieves a constant oil temperature.

  • Page 73: Pneumatic System

    4.12 Pneumatic system Compressed air piping for the pneumatic system must be expertly laid and installed. Fittings, length and cross section have to meet the requirements! Work at the pneumatic system may only be carried out by a skilled pneumatic technician! If the compressed air system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! 4.12.1...
  • Page 74 SM1GB0GB Chapter 4.12 - 2 00616TW...

  • Page 75: Electrical Equipment

    4.13 Electrical equipment The IMM may only be connected to a power supply which corresponds in phase, voltage and frequency to the data given on the electrical specifi cation plate. Electrical installation may only be carried out by a qualifi ed electrician (qualifi ed to DIN VDE 0105 or IEC 364 or equivalent)! The electrical supply lines must be designed according to the specifi...
  • Page 76 Separate leads for drive and heating without neutral 4 (L1, L2, L3, E) 4 (L1, L2, L3, E) Separate leads for drive and heating with neutral 4 (L1, L2, L3, E) 5 (L1, L2, L3, N, E) Checking the direction of rotation of the hydraulic pump’s drive Before switching on the IMM it must be ensured that: •...
  • Page 77 • Switch on the supply voltage (low voltage distribution). • The phase sensor should now indicate a right-hand (clockwise) fi eld. • Switch off the supply voltage (low voltage distribution) if the direction of rotation is not correct and exchange two phases of the power connections 1L1, 1L2, and 1L3 of the mains lead in the switch cabinet.
  • Page 78 HM6GB0HA Chapter 4.13 - 4 0414TW...
  • Page 79 Mould mounting Preparation If the machine has a robot interface and the machine is to be run without the robot, then the latter should be switched off and the supplied dummy plug must be inserted. Operation of the machine without this linking out is not possible. The installation of the links is detailed under "Interfaces".
  • Page 80 After the control boots up the "Start page" screen page will appear. Press the "Alarms" menu key; a list of the active error messages will be displayed, including the "Oil heating - Tolerance" error message. This error message disappears automatically as soon as the hydraulic oil comes up to operating temperature.
  • Page 81 The lifting equipment should not be removed until the mould is bolted securely on the rotary tabletop and this has been verifi ed by an authorised technician! Do not loosen the safety strap holding the two mould halves together! ATTENTION The number of mould clamps must be adapted to the mould weight and the opening force of the machine! 11.5 In the setting mode, turn the rotary table into the clamping station (station A)
  • Page 82 12.3 Press the "Mould open" key and open the nozzle platen. 12.4 For installing several lower moulds, paragraphs 11.3 to 12.4 must be repeated. Set clamping force 13.1 Press the "Manual operation" key. 13.2 Press the "Clamping unit" menu key. The "Clamping unit"...
  • Page 83 ATTENTION The cables must be laid and installed as not to be damaged by the mould or the machine. Connect the mould heating and cooling. ATTENTION Please note the correct passage direction since the cooling may otherwise be subject to negative infl...
  • Page 84 Clamp the upper mould to the nozzle platen by activating the wedge clamping elements of the "Mouldfi x" for the nozzle platen until reaching the "Wedge clamping elements released" limit switches. If the limit switches have not been reached the movements of the clamping platen will be disabled.

  • Page 85: Checking The Safety Devices

    Checking the safety devices The safety devices can only fulfi l their purpose if their faultless operation can be guaranteed. Therefore it is necessary to check the following for effective function before operation: The function test for the safety device may only be carried out by a trained and skilled technician! •...
  • Page 86 ATTENTION It is essential to select "Setting" mode, or else the test run may damage the mould! Check the movements of the various units as follows: • Switch on main switch (to "1"). • Check the safety device as described in the "Checking safety devices" paragraph. •...

  • Page 87: Structure And Function

    Structure and function Clamping unit Injection unit Hydraulic (option) Pneumatics (option) Electrics Control VR2GB0JB800A 0217TW Chapter 6 - 1...
  • Page 88 VR2GB0JB800A Chapter 6 - 2 0217TW...
  • Page 89 Clamping unit 6.1.1 Clamping unit VM R Technical description Rotary table Support platen Nozzle platen Connecting platen Piston rod 3 clamping cylinders Piston rod Connecting platen Cylinder Guide rails (for horizontal injection unit only) Tiebar nut VMRGB0KD 1116TW Chapter 6.1 - 1...

  • Page 90: Description Of Functions

    Description of functions: The clamping unit can be considered as an independent assembly attached to the machine body by bolts in the support platen for the rotary table. The clamping force is applied by three clamping cylinders. The symmetrical 3-point force introduction ensures optimum force distribution.
  • Page 91 6.1.2 Clamping unit VM Support platen Ejector Nozzle platen Connecting platen Cylinder Connecting platen Piston rod 4 clamping cylinders Guide rails (for horizontal injection unit only) Piston rod Tiebar nut VMRGB0KD 1116TW Chapter 6.1 - 3...
  • Page 92 Description of functions: The clamping unit can be considered as an independent assembly attached to the machine body by bolts in the mould mounting platen. The clamping force is applied by four clamping cylinders. The 4-point force introduction ensures optimum force distribution. This system guarantees highest precision during the movements of the clamping unit.
  • Page 93 6.1.3 Central lubrication pump Design: Direct current motor Screw drive Eccentric shaft Piston Piston outlet screwing Delivery piston Grease sieve Agitator blade Grease container Follow-up piston Conical-screw spring Tracer pin Overfi ll protection VMRGB0KD 1116TW Chapter 6.1 - 5...
  • Page 94 Description of functions The central lubrication pump is an electrically driven lubrication pump. In the standard verisin the pump is equipped with an electrical level indication. When reaching the minimum grease level, this level indication will switch off the pump so that no air can be sucked into the system.

  • Page 95: Injection Unit

    Injection unit 6.2.1 Technical description The main components of the injection unit (or carriage) are the screw barrel (1), the nozzle contact cylinder (2), the injection cylinder (3), the drive and bearings (4), hydraulic motor (5), the material hopper and the support. Low maintenance linear bearings enable precise axial movements of the injection unit.
  • Page 96 A proximity switch records the screw speed and transfers it to the control. A stroke transducer, on the rear side of the machine, records the stroke of the screw and transfers it to the machine control. The injection unit ensures a high plasticising rate, achieved partly by an optimised L/D (= length / diameter) ratio.
  • Page 97 6.2.2 Screw drive Before checking, the machine must be switched off at the main switch and must be secured against accidental reconnection! The axial bearing of the injection unit is arranged so that the leakage line from the hydraulic motor lubricates it. No maintenance is thus necessary in this case. The oil level must be checked before the fi...
  • Page 98 6.2.3 Adjusting the nozzle centre Injection unit up to size 1330 Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! Measure the centricity of the nozzle with a caliper gauge by measuring the distance from the nozzle bore to the opening in the platen at several places - at least four.
  • Page 99 6.2.4 Basic requirement for changing the nozzle Press the "Setting" key. Set peripheral equipment (option) to the starting position and switch off any peripheral equipment according to its operating manual. Switch off material feeder (option). Only for Airmould ® nozzle:Shut off the nitrogen supply to the Airmould ®...
  • Page 100 Close the "Protective guard" of the "Nozzle". Eject the residual moulding compound at short intervals. Purge the screw barrel with an appropriate cleaning material. Consult your plastics manufacturer about the suitable material. Switch off water system, pneumatic system, modular Airmould system (option). See also the paragraph "Shutting down the machine"...
  • Page 101 6.2.4.1 Changing "open” nozzles Figure 1 Open nozzle Figure 2 Open Airmould® nozzle, pressure-controlled Basic requirement paragraph 1-20 (chapter 6.2.4) Dismantle the heater band of the "Nozzle" (1). Position a hexagon spanner on the "Hexagon" (3) and unscrew the "Nozzle" (2). Only for Airmould nozzle: ®...
  • Page 102 Lubricate the thread of the new or cleaned "Nozzle" with a high-capacity assembly paste. It must be water-repellent, corrosion-proof, material-indifferent, and heat-resistent (at least up to 350 °C / 662 °F). Check the contact surfaces for damage and wear before mounting. When fi...

  • Page 103: Nozzle Changing

    6.2.4.2 Nozzle changing Working data Shut-off nozzles max. injection fl ow Back pres- Injection pres- System pres- Nozzle contact force Temperature Lever length/stroke Activation (ccm/sec./cinch/sec.) sure (bar/ sure max. (bar/ sure pneum./ max. (kN/sh ton) max. (°C/°F) (mm/inch) (HP) psi) psi) hydr.
  • Page 104 6.2.4.2.1 Replacing the "Herzog" needle shut-off nozzle of type SHP, spring-controlled Body Needle guide bush Fixing pin Thrust ring Spring assembly Adaptor Shut-off needle Nozzle head Heater band Temperature probe VMRGB0LB Chapter 6.2 - 10 1116TW...
  • Page 105 Basic requirement paragraph 1-20 (chapter 6.2.4) If necessary, unscrew "Temperature probe" (10) Dismantle the heater band of the nozzle (9) Screw out the nozzle head (8) Withdraw the shut-off needle (7) Screw off the "Adaptor" (6) Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Neddle seal nozzle".
  • Page 106 Mount the needle valve nozzle in reverse order Screw the adaptor (6) home by hand but do not fi nally tighten Insert the shut-off needle (7) Screw the nozzle head (8) home by hand but do not fi nally tighten Mount the heater band (9) of the nozzle If necessary, screw the temperature probe (10) home by hand but do not fi...
  • Page 107 6.2.4.2.2 Changing the "Fuchslocher” needle valve nozzle Nozzle body Spring chamber Compression spring Heater band Shut-off needle Nozzle head Basic requirement paragraph 1-20 (chapter 6.2.4) Screw out the temperature probe Dismantle the heater band (4 from the nozzle head (6). Position a hexagon spanner on the "Hexagon"...
  • Page 108 Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.
  • Page 109 Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl ying out! Tightly screw in the "Nozzle" and "Nozzle body" after heating to operating temperature. Torque setting: Nozzle head (6) - 300 to 350 Nm (221 to 258 ft lb).
  • Page 110 6.2.4.2.3 Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP, with integrated control cylinder Nozzle head Shut-off needle Fixing pin Lever bolt Lever Screws heater band Temperature probe Adaptor Yoke / adaptor ring Control cylinder VMRGB0LB Chapter 6.2 - 16 1116TW...
  • Page 111 Basic requirement paragraph 1-20 (chapter 6.2.4) If necessary, unscrew temperature probe (8). Dismantle the heater band (7) of the nozzle. Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from the control cylinder (11) and remove the lever (5). Screw out the nozzle head (1).
  • Page 112 Mount the needle valve nozzle in reverse order. Screw the adaptor (9) home by hand but do not fi nally tighten. Insert the shut-off needle (2). Screw the nozzle head (1) home by hand but do not fi nally tighten. Mount the heater band (7) of the nozzle.
  • Page 113 Tighten all screws crosswise Torque 1st step Prefi xing Prefi xing Prefi xing 2nd step 7 Nm 15 Nm 35 Nm 3rd step 10 Nm 22 Nm 45 Nm 4th step 12 Nm 25 Nm 50 Nm Connect pneumatic hoses or hydraulic hoses (according to the kind of triggering) to the control cylinder (12) and mount the lever (5).
  • Page 114 6.2.4.2.4 Replacing the pneumatically triggered "Herzog” bolt valve nozzle, type HP, with integrated control cylinder Nozzle head Bolt lock Lever bolt Lever Screws Heater band Temperature probe Adaptor Yoke / adaptor ring Control cylinder Shut-off nut Body VMRGB0LB Chapter 6.2 - 20 1116TW...
  • Page 115 Basic requirement paragraph 1-20 (chapter 6.2.4) If necessary, unscrew temperature probe (7). Dismantle the heater band (6) of the nozzle. Disconnect pneumatic hoses or hydraulic hoses (according to the kind of triggering) from the control cylinder (10) and remove the lever (4). Screw out the nozzle head (1).
  • Page 116 Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.
  • Page 117 Switch on main switch. Switch on hydraulics ("Hydraulics Start" key). Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl...
  • Page 118 6.2.4.2.5 Replacing the pneumatically or hydraulically triggered "Herzog" needle valve nozzle, type HP Adaptor Temperature probe Heater band Nozzle head Screws Rod assembly Basic requirement paragraph 1-20 (chapter 6.2.4) If necessary, unscrew temperature probe (2). Dismantle the rod assembly (6). Dismantle the heater band (3) of the nozzle.
  • Page 119 Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.
  • Page 120 Switch on main switch. Switch on hydraulics ("Hydraulics Start" key). Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl...
  • Page 121 The nozzle is delivered as sub-assemblies. The fi nal assembly is made on the machine After having aligned the rod assembly with the nozzle, the fl ange bolts can be tightened crosswise in four steps. The gap between body and adaptor ring can change between 0.5 and2.5 mm (0.02 and 0.1 inch).
  • Page 122 6.2.4.2.6 Replacing the pneumatically or hydraulically triggered "Fuchslocher" needle valve nozzle Nozzle body Thrust ring Heater band Nozzle head Shut-off needle Fork Basic requirement paragraph 1-20 (chapter 6.2.4) If necessary, unscrew temperature probe. Dismantle the heater band (3). Dismantle the rod assembly from the fork (6). Screw out the nozzle head (4).
  • Page 123 Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.
  • Page 124 Switch on main switch. Switch on hydraulics ("Hydraulics Start" key). Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl...
  • Page 125 6.2.4.2.7 ENG pneumatic needle valve nozzle with integrated control cylinder Nozzle body Control cylinder Rod assembly Nozzle head Body Tension nut Basic requirement paragraph 1-20 (chapter 6.2.4) If necessary, unscrew temperature probe. Dismantle the heater band. Dismantle the rod assembly (3). Screw out the nozzle head (4).
  • Page 126 Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Neddle seal nozzle". Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.
  • Page 127 Switch on main switch. Switch on hydraulics ("Hydraulics Start" key). Switch on "Nozzle" and "Barrel" heating and heat up to operating temperature. Risk of injury and burning if the nozzle or its heater are touched. Wear appropriate personal protective equipment! The operator must without fail ensure proper assembly of the nozzle to prevent risk of its fl...
  • Page 128 6.2.5 Dismantling the screw barrel / screw 6.2.5.1 Dismantling the screw up to size 1330 Dismantle the "Nozzle" as described in the paragraph "Dismantling the nozzle". Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical stop.
  • Page 129 Dismantle the cover of the "Guarding" of the "Injection cylinder". ATTENTION Only use tools and aids which do neither damage the nozzle nor its components described below! Slightly unscrew the "Screws" (1) of the "Clamping disc" (2) and remove the two "Wedges"...
  • Page 130 Secure the "Screw" with a corresponding aid and pull it out of the "Screw barrel" to the front. For the weight of the "Screw", see the "Technical data" chapter. If necessary, unscrew the "Screw tip" as described in this chapter. Danger of injury and damaging components! Only parts (nozzle, screw, barrel and its fi...
  • Page 131 6.2.5.2 Retooling for a different screw diameter up to size 1330 Danger of injury and damaging components! Only components that were either supplied or specifi ed by Battenfeld should be implemented! If components of the machine are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for installation, dismantling, modifi...
  • Page 132 With a "Screw" with a smaller diameter, mount the supplied "Sleeve" onto the "Screw shaft" (push on). Push the "Screw shaft" into the "Thrust piece" to the stop. Adjust the "Screw shaft" so that the "Wedges" can engage in the cut. Insert the new "Wedges"...
  • Page 133 Dismantle the "Extension" of the "Piston rod" of the "Nozzle contact cylinders". Mount the "Extension" of the "Piston rod" of the "Nozzle contact cylinders" for the current "Screw barrel". The key surface (1) must be vertically positioned to ensure proper closing and opening of the purge guard.
  • Page 134 Scre in the "Screws" of the "Nozzle contact cylinders" at the "Nozzle platen". Press the "Injection unit back" key. Move the "Nozzle contact cylinder" to the mechanical stop. Mount the "Nozzle" in reverse order as described in the paragraph "Dismantling the nozzle".
  • Page 135 "Screw tip" with "Back fl ow check with ring". Fire hazard! Use no fl ammable solvents! Thoroughly clean the components of the "Screw tip”. Use wire brush or brass brush. Thoroughly remove old grease residues in the thread gaps. Cleaning with a gas burner, a sand blast system, or by glowing out will cause the loss of the mechanial and technological characteristics of the components.
  • Page 136 6.2.6 Cleaning the barrel, material changes The increasing requirements for quality fi nished plastic articles necessitate the frequent and thorough cleaning of all components which come into contact with plastics. 6.2.7 Purging out with virgin polyethylene This process ensures an almost total purging of the previous material. However the polyethylene must in turn be forced out of the screw and barrel by the new material.

  • Page 137: General Information

    Hydraulics 6.3.1 General information The IMM hydraulic system has a number of benefi cial features: • Easily accessible hydraulic system. • Energy saving pump with electric adjustment enables smooth movements with high precision and extremely short dry cycle times. • The hydraulic components are arranged so that pipes and hoses are reduced to a minimum.

  • Page 138: Pressure Fi Lter

    6.3.4 Pressure fi lter To improve the reliability and longevity of the hydraulic components and seals, a non-bypass pressure fi lter (fi lter mesh 5 μm absolute) is provided in the main pressure line of the hydraulic system. The pressure fi lter is fl anged to the pump block and can be accessed from outside. The pressure fi...

  • Page 139: Pressure Setting

    The oil temperature values depend on the oil viscosity used (HLP32/HLP46) (see chapeter 3.1.2). The WITTMANN BATTENFELD GmbH recommends HLP 32! As soon as the hydraulic pump is started, the cold hydraulic oil is automatically preheated until the hydraulic oil has reaced the operating temperature (see chapter 3.1.2).
  • Page 140 6.3.10 Hydraulic core puller The hydraulic core puller (option) consists of a base plate on which the required hydraulic valves are installed and which includes the user connections (NW 6 or NW 10). This function module is mounted on the clamping block or pump block. The hose assemblies and fi...

  • Page 141: Air Supply Unit

    Pneumatics 6.4.1 Pneumatic core puller The pneumatic core puller (option) comprises an electrically actuated 5/2 pneumatic valve and all the consumer connections for a 6 mm (0.24 inch) bore plastic pipe. This function module is mounted onto the central console or on the media block of the clamping platen.
  • Page 142 VMRGB0NB Chapter 6.4 - 2 0616TW...
  • Page 143 Airmould The Airmould unit (option) enables the manufacture of high quality injection moulded articles with gas voids by gas injection. For this reason, the injection moulding machine, for example, may be operated with shorter cycle times and lower clamping forces. The defi...
  • Page 144 The main parts of the pressure generator are a high pressure compressor, drive motor, gas bag, and accumulator bottles. A nitrogen generator can be arranged as a separate unit or integrated into the pressure generator, as the customer wishes. EWAGB0OB Chapter 6.5 - 2 0814TW...
  • Page 145 Electrics 6.6.1 Electric drive 6.6.1.1 Three phase asynchronous motor The pump unit is driven by a three phase asynchronous motor. The drive motor is coupled directly to the hydraulic pump and connected to suit the operating voltage. When connected correctly (the phase sequence must give a righthand fi eld, see "Transport - Installation"...

  • Page 146: Switch Cabinet

    6.6.2 Switch cabinet The electrical cabinet is easily accessed on the rear side of the IMM and contains most of the electrical components necessary for operation. Main switch Door latch Mounting plate, sockets Main supply VMRGB0PA Chapter 6.6 - 2 0814TW...

  • Page 147: Operator Panel

    UNILOG B8 is the new generation of control units which sets the standard regarding operator friendlinesss, speed and precision. The continuity of the Wittmann Battenfeld philosophy and symbolism regarding operation is ensured by taking over the components from the previous control system - with an additional enlargement of the graphical user interface.
  • Page 148 6.7.3 Explanation of the picture SmartScreen With the SmartScreen functionality, the UNILOG B8 offers the possibility to divide the screen in two independent display area in order to show and operate two different functions at the same time. SM2GBQB800B Chapter 6.7 - 2 0117TW...
  • Page 149 QuickSetup The QuickSetup assistance program is the machine version of the mobile "WiBa-Assist" app. Its advantage is a quick and uncomplicated programming of initial settings of the production system. After selecting the material data from a data base and entering the dimension data of the injection mould, the program automatically determines an initial setting which can be adopted for starting the production.
  • Page 150 Standard software Already in the standard version, the machine control is equipped with a comprehensive package of user software which can be used to optimise the cycle fl ow and increase the process precision. Included are: Melt Monitoring (metering monitoring) Flow Monitoring (injection monitoring) Cushion Monitoring (melt cushion monitoring) The basis for process monitoring is the recording of a distance-based measurement value...
  • Page 151 SM2GBQB800B 0117TW Chapter 6.7 - 5...
  • Page 152 Optional software HiQ software and Expert systems are further option package which are available for controlling demanding processes. HiQ-Melt (monitoring the material quality) HiQ Melt is a method for monitoring the material quality. Measurand is the energy used for plastication. It is measured via the screw torque along the plastication stroke, issued as value and monitored within a tolerance range.
  • Page 153 Thus, venting via the parting surface and therefore mould fi lling will become easier. An economically relevant side effect is the resulting saving of drive energy. EXPERT-Venting Mould opening for mould venting, e.g. combined with thermoset processing With the internal, the WITTMANN group has SM2GBQB800B 0117TW Chapter 6.7 - 7...
  • Page 154 SM2GBQB800B Chapter 6.7 - 8 0117TW...
  • Page 155 WITTMANN 4.0, the WITTMANN group has a uniform data transfer platform between injection moulding machine and WITTMANN peripheral devices. When changing the device, the correct operating software in the sense of "Plug & Produce" is automatically loaded via an update function.
  • Page 156 SM2GBQB800B Chapter 6.7 - 10 0117TW...

  • Page 157: Saving / Printing

    External security The WITTMANN communications architecture guarantees the highest possible level of data security. Within on production cell, the machine's communication with the peripheral devices is made via an internal local network. Communication to the outside is made by the production cell via a fi...

  • Page 158: Control Components

    6.7.5 Control components System structure Overview of the Unilog hardware structure Multi-touch display unit and key unit Ethernet Powerlink connection (EPL) X20 I/O system SM2GBQB800B Chapter 6.7 - 12 0117TW...
  • Page 159 Multi-touch display unit The display unit is composed of the following components: a 5AP93D.215I-K01 display, the industrial PC PPC900, and the housing. Taken together, these components form the complete operating unit. The resolution is full-HD (1920 x 1080). Cleaning: A separate program is made available for cleaning the display unit in order to avoid the release of unintended functions.
  • Page 160 4B400.00-K61 operating panel Is used to operate the basic machine functions and special equipment. The key assignment is confi gured via the multi-touch screen. • Voltage supply: +24 VDC • Bus interface: 2 x CAN Open SM2GBQB800B Chapter 6.7 - 14 0117TW...
  • Page 161 Panel PC The Automation PC with Intel® Core i technology is available for applications with the highest demands in terms of processor performance. These processors, which were especially developped for mobile computing, offers many advantages for industrial use, too. High computer power is combined with low power input.
  • Page 162 Battery: The lithium battery (3V, 950 mAh) buffers the internal real-time clock (RTC) and is located at the rear side of the panel PC. The battery is installed in a battery holder and can thus be exchanged very easily. The buffer duration of the battery is at least 4 years (at 50°C, 8.5 μA of the components to be supplied and a self-discharge of 40 %.
  • Page 163 I/O modules Three basic elements form a single module: Bus module - electronic module - fi eld terminal Easy installation - ingenious top-hat rail installation for optimum system handling Stable triangle arrangement - direct connection between bus module and terminal block Wide range of products - allows optimum adaptation for every task Galvanically insulated - reliable operation under the toughest conditions Diagnosis - on-site visual diagnosis, remote via software and electronic type plate...
  • Page 164 X20BC0083 The BC0083 Bus Controller enables the connection of X2X Link I/O nodes (modules) to POWERLINK (standard protocol for Fast Ethernet). X20PS9400 The PS9400 supply module is used together with an X20 Bus Controller (e.g. X20BC0083). It is equipped with a supply for the Bus Controller, the X2X Link and the I/O supply. X20DI9371 The module DI9371 has 12 inputs in single conductor technology.
  • Page 165 X20AO4632 The module AO4632 has four outputs with 16-bit digital converter resolution. It can be switched between current and voltage signal (+/- 10V DC) with the aid of different connection terminals. X20AT6402 The module AT6402 has six inputs for J, K, N and S thermocouple sensors. A terminal temperature compensation is integrated in the module.
  • Page 166 SM2GBQB800B Chapter 6.7 - 20 0117TW...

  • Page 167: Operation

    Operation Miscellaneous For a number of reasons we would recommend commissioning of the IMM by Battenfeld personnel. This is not only for warranty reasons, but because at the same time: • The machine can be checked for any transport damage or installation and connection faults.

  • Page 168: Initial Start-Up

    Initial start-up Observe the operating manual and in particular the safety regulations in the "Safety" section. Unload, transport, install and level the machine as described in the "Transport - Installation" section. Prepare the hydraulic system as described in the chapter "Transport - Installation". Prepare the water system as described in the "Transport - Installation"...

  • Page 169: Starting The Machine After Emergency Stop

    Open and close the safety gate and purge guard (to test the safety gate monitoring circuit) It is forbidden to stand on the machine or to reach into the injection unit during operation! Carry out the test run and interlock test as described in the "Transport - Installation" chapter Carry out the test run without / with material as described in the present section.
  • Page 170 Test run without material After commissioning or changing the mould, the movements of the various units should be tested before running a few manual cycles with a mould mounted. The safety regulations in the chapter "Safety" are to be followed without fail! Check whether the switch cabinet, safety guards and safety gates have been properly installed or closed.
  • Page 171 Before operating the machine the safety regulations in the operating manual(s) of any peripheral equipment must be followed without fail! Commission peripheral equipment (option) according to the operating manuals and set them to the starting position, i.e. the position in which no damage to the devices or to machine components is possible.
  • Page 172 Fire hazard! No smoking! Make sure that there are no fl ammable liquids, open fl ame, etc. near the screw barrel heating or barrel cooling (option)! No drawn-in material or explosive air mixtures may be near the inlet area of the radial fans to the barrel cooling (option)! Remove all materials, liquids and objects which should not be near the injection unit.
  • Page 173 Press "Automatic mode" key. Operating and other personnel may only stand in front of the machine on the operator’s side during operation! Press "Mould close" key; an automatic cycle is started. The "Semiautomatic" modes can be started by closing the safety gate (option). In case of power-operated safety gates at the clamping unit, these gates will be opened automatically at the end of the cycle in the "Semiautomatic"...
  • Page 174 Filling the material hopper Make sure that the main switch is switched off and secured against unauthorised reconnection. Surfaces marked with the "No step" symbol must not be stood on! If the material hopper, the material feeder or the stuffi ng device are located higher than the average body height, climbing aids and working platforms which meet the legal safety requirements must be used for fi...
  • Page 175 Test run with material The safety regulations in the chapter "Safety" are to be followed without fail! Prepare the machine as described in chapter "Test run without material", steps 1 to 3. Fill material as described in section "Filling the material hopper". Prepare the machine as described in chapter "Test run without material", steps 4 to 18.
  • Page 176 Select the desired program "Automatic” or "Semiautomatic” Depending on the program selection either press the "Close mould" key or close the safety gate (see step 22 in the "Test run without material" section) to start the machine. In this way several cycles are run. The movements of the various units, the settings and the quality of the mouldings are now to be checked.
  • Page 177 Operation The operation of the machine does not differ from the procedure described in paragraph "Test run with material" and the procedures described in this section. After each shutdown and before each start-up of the machine, the safety devices have to be checked after switching on the main switch as described in the "Transport - Installation"...

  • Page 178: Shutting Down The Machine

    Shutting down the machine Press the "Manual operation" key. Set peripheral equipment (option) to the starting position and switch off any peripheral equipment according to its operating manual. Switch off the "UNIFEED" material feeder (option). Pull the hopper away from the feed throat of the barrel Move the core pullers out of the mould if appropriate.

  • Page 179: Extended Shutdown

    7.10 Extended shutdown Shut down the machine as described in "Shutting the machine down”. Swing the material hopper to the emptying position and fi ll the remaining material into an appropriate container. First free the screw barrel and the screw from the remaining melt and purge out with polyethylene.

  • Page 180: Shutdown Procedure

    7.11 Shut down procedure Shut down the machine as described in "Shutting the machine down”, steps 1 to 10 Preserve the cavities of the mould according to the manufacturer’s instructions. 7.11.1 Dismantling the mould In this paragraph the dismantling of a mould fastened with mould clamps is described. The dismantling of a mould fastened with a quick-action mould mounting system basically corresponds to the following description.
  • Page 181 Danger of death! It must be ensured that no persons stand or linger under the suspended load! Lift the mould horizontally out of the opened clamping unit. Protect the mould according to the mouldmaker’s instructions and prepare it for storage. 7.11.2 Further measures for shutting down Let the heating elements and their guardings, temperature control units and their fl...
  • Page 182 7.11.3 Emptying the hydraulic system Work at the hydraulic system may only be carried out by a skilled hydraulic technician! For a hydraulic system with integrated pressure accumulator (option) defl ate the nitrogen as described in section "Transport - Installation". Burning hazard if touched! At oil temperatures above 50 °C (50.00 °C) wear appropriate PPE! Avoid any skin contact! If hydraulic oil gets into the eyes, rinse carefully with water and consult a physician!
  • Page 183 Place the venting fi lter on the pipe socket again. Remove the tank cover and clean the hydraulic tank Remove the housing of the hydraulic fi lter. Dispose of the liquid in a suitable container, see chapter "Maintenance", "Hydraulic fi lter" paragraph. When storing and disposing of hydraulic oils and used oil the local laws and regulations are to be followed without fail.
  • Page 184 7.11.4 Emptying the cooling water supply If the cooling system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! Burning hazard if touched! At water temperatures above 50 °C (50,00 °C) wear appropriate PPE! Cut off the water supply to the oil cooler Cut off the water supply (1) to the cooling water fl...
  • Page 185 7.11.5 Evacuating the compressed air system If the compressed air system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! Cut off the compressed air supply to the air supply unit. Turn the pressure control valve setting knob (1) counterclockwise until the pressure gauge (2) has dropped to 0 bar.
  • Page 186 7.11.7 Disconnecting the electric system The machine may only be disconnected from the power supply by a skilled electrician. The safety regulations in the chapter "Safety" are to be followed without fail! Switch off the supply voltage (low voltage distribution) to the machine. Disconnect the supply lines in the switch cabinet from the mains and the heating power terminals.
  • Page 187 Maintain hydraulic system After extended shutdown, in particular, if there are extreme climatic conditions, the movement of some hydraulic components (e.g. valves) may be restricted due to gumming or precipitations within the hydraulic oil. For this reason the machine should be carefully restarted at low set values for the movement speeds and pressures.
  • Page 188 7.14 Disposal The proprietor is obliged to dispose of all components, lubricants, hydraulic and gear oil as well as other aids (cleaning cloths, cleaning agents, etc.) according national and international laws and regulations. This applies especially to those components which have been in contact with products hazardous to the environment (lubricants, hydraulic and gear oils).

  • Page 189: Maintenance

    Maintenance Miscellaneous Careful installation and care are necessary for the reliable functioning of the injection moulding machine (hereinafter machine). Daily visual checks help to prevent down times. Checks, maintenance work and the exchange of worn out parts should be undertaken at regular intervals. Only parts of the same quality (strength, material) and design may be used.

  • Page 190: Disposal Of Electrical And Electronic Components

    In principle, such a change of oil type should not be made since extensive technical problems could be caused. Wittmann-Battenfeld will not grant an approval! VMRGB0SF Chapter 8 - 2...
  • Page 191 Only use prefi ltered hydraulic oil of cleanliness class 17/15/12 acc. to ISO 4406! Gearbox, axial Central lubri- Three-phase Pneumatics & Hydraulic Hydraulic Central oil Linear Lubrication point bearing and cation grease motor & electric electromagne- equipment*) equipment***) lubrication guide oil lubrication and grease motors**)

  • Page 192: Maintenance Chart

    Maintenance chart Every 160 operating hours • All safety devices or all safety guards installed (including the mechanical scotch) • Oil level in hydraulic tank • Overall condition of machine (visual check). • Always keep the switch cabinet doors closed. •...
  • Page 193 Every 2500 operating hours • Operating manual available and correct. • Check the heater bands for correct position and secure fi tting. • Tighten all terminals in the switch cabinet. • Check cables (for damage, scorching). • Clean the fi lter mat(s) of the switch cabinet, fan. •...

  • Page 194: Oil Change

    Hydraulic system Work on hydraulic system may only be carried out by a skilled hydraulic technician! If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury! Switch off the main switch and use a padlock to prevent accidental reconnection.
  • Page 195 ATTENTION Leaked oil is always contaminated and must never be put back into the hydraulic tank! Ensure greatest cleanliness! The fi lling spout on the hydraulic tank, as well as the fi lling screws and screw plugs on the transport and storage tank of the hydraulic oil and the surroundings must be thoroughly cleaned beforehand;...

  • Page 196: Checking The Oil Level

    To avoid mixing oils it is recommended to mark the oil tank and fi llers with the oil type. Fill the hydraulic tank to the maximum mark with a mobile fi ltration unit The max. fi lling level is shown by the upper marking on the oil level indicator. Place the venting fi...

  • Page 197: Hydraulic Fi Lter

    8.6.4 Oil change Axial bearing ATTENTION The oil level should be checked daily. The axial bearing should be checked daily for leaks and damage to the shaft seals. 8.6.5 Hydraulic fi lter Pressure fi lters are installed in front of components which require extra protection. The pressure fi...

  • Page 198: Changing The Fi Lter Element

    8.6.6 Changing the fi lter element • Switch off the machine and wait for complete pressure loss. If the hydraulic system is not relieved of pressure before work is started it may empty explosively with the risk of damage and injury! Burning hazard if touched! At oil temperatures above 60 °C (60,00 °C) wear appropriate PPE! •...
  • Page 199 • Inspect the fi lter unit for mechanical damage, especially to sealing faces and seals. Renew damaged parts. Check O-rings (3 + 4) and change if damaged. ATTENTION If damaged components are not replaced and if the fi lter is not kept in perfect condition, other hydraulic components may be damaged or fail! •...
  • Page 200 8.6.7 Venting fi lter Venting fi lters allow fi ltered air to pass in and out of the oil tank as the oil level changes. Its effectiveness depends upon the environment, but it should be checked and if necessary the element renewed after 2500 operating hours at the latest, paying the greatest attention to cleanliness.

  • Page 201: Oil Cooler

    8.6.8 Leaks Observe any leaks in the hydraulic system and remedy them by resealing or tightening the screw connections. Damaged hydraulic hoses and hose assemblies must be renewed at once, please refer to the chapter "Hose assemblies". Regular checks of the hydraulic fi ttings, hose asemblies, cylinders, valves, pump(s) etc. must be carried out every 160 running hours.
  • Page 202 Pressure vessel Work at pressure vessels may only be carried out by specially trained personnel! Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released! Risk of explosion! Only use nitrogen "N2"...
  • Page 203 8.7.2 Replenishing, reducing and testing the nitrogen pressure The fi lling and testing unit is not included in the standard delivery. 1 - Connection for the nitrogen cylin- der (Right-hand thread W24.32x 1 1/4") 2 - Non-return valve (valve insert) 3 - Button 4 - Pressure pin 5 - Valve gate...

  • Page 204: Checking The Hydraulic Pressure

    8.7.3 Checking the hydraulic pressure Work at pressure vessels may only be carried out by specially trained personnel! Work on plants with pressure vessels (repairs, connections of a pressure gauge or the like) must not be carried out until the hydraulic pressure (oil) has been released! Risk of explosion! Only use nitrogen "N2"...

  • Page 205: Inspection Criteria

    Hoses which have already been in service as part of a hose assembly may not be reused as they no longer conform to the requirements of DIN 20066. If a hose is reused, then the liability lies with the person who fi ts the hose assembly. Only hose assemblies with swaged-on stand-pipe ends can be reused.

  • Page 206: Hydraulic Accessories

    Hydraulic accessories If the machine’s hydraulic system is equipped at the customer’s wish with additional components, like bypass fi ltration units, then the corresponding operating instructions in the "Accessories" section of this technical documentation must fi rst be read, in its entirety, without fail.

  • Page 207: Corrosion Protection

    8.10.3 Screw drive Before checking, the machine must be secured against accidental reconnection! The axial bearing is arranged so that the leakage line from the hydraulic motor lubricates it. No maintenance is thus necessary in this case. The oil level must be checked before the fi rst start-up and, if necessary, oil must be fi lled in or refi...
  • Page 208 8.11 Water system ATTENTION When using water piping note the corrosion stability of metallic materials against water in accordance with DIN 50930! Water piping and the respective fi ttings are to be weekly checked for corrosion and leakages by a skilled technician. If the cooling system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! Burning hazard if touched! At water temperatures above 50 °C (122 °F) wear appropriate...

  • Page 209: Hydraulic Oil Temperature

    8.11.3 Hydraulic oil temperature The optimum effi ciency of the machine is at an oil temperature (see chapter 3.2). The current hydraulic oil temperature will be displayed on the screen (B2 = in the actual value fi eld "T12" on page 2 of the "Temperature control zones" screen page / B4 = "Barrel temperatures 1"...

  • Page 210: Filter Mats

    8.12 Electrical equipment For all work involving fi tting, removal, modifi cation and maintenance, the legal rules and regulations and the safety instructions in the "Safety" chapter must be observed without fail! Work on electrical components may only be carried out by a qualifi ed electrician! 8.12.1 Filter mats The fi...
  • Page 211 Take out the lithium battery (do not touch the battery with pliers or uninsulated tweezers -> short circuit). Only touch the battery on the front side with your hands. Insulated tweezers can also be used to take out the battery. Position the new battery with the correct polarity.
  • Page 212 8.13 Pneumatic system If the pneumatic system is not relieved of all pressure before work starts, there is a risk of explosive emptying with possible damage or injury! 8.13.1 UNIFEED material feeder The secondary fi lter (3) of UNIFEED material feeder (option) should be cleaned as necessary and in any case inspected at least once a week, depending on the amount of dust.

  • Page 213: Filter Cartridge

    8.13.2 Air supply unit The oil level of the air supply unit (option) should be checked every 8 operating hours and topped up if necessary. The oil grade is given in the "Hydraulic oils and lubricants table". 8.13.3 Filter cartridge The interval for cleaning depends on the amount of dirt in the air.
  • Page 214 VMRGB0SF Chapter 8 - 26 1216TW...
  • Page 215 In order to avoid misunderstandings, it is necessary to give the Machine Number with every spare parts order. In addition please state the Identifi cation number (ID No.), the Designation and the desired Quantity. When ordering, please contact the Wittmann Battenfeld GmbH agency responsible for you or contact Wittmann Battenfeld GmbH directly. EWAGB0TB...
  • Page 216 EWAGB0TB Chapter 9 - 2 0814TW...
  • Page 217 Special descriptions EWAGB0UB 0814TW Chapter 10 - 1...
  • Page 218 EWAGB0UB Chapter 10 - 2 0814TW...

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