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Funcional - Operating Maplan

operacion de mauquina Maplan

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Aldebaran Alcazar
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197 views48 pages

Funcional - Operating Maplan

operacion de mauquina Maplan

Uploaded by

Aldebaran Alcazar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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MAPLAN MASCHINEN U. TECHN. ANLAGEN PLANUNGS- UND FERTIGUNGS-GES.M.B.H. FUNCTIONAL DESCRIPTIO Injection moulding machine Valid for the following models: MHF .../ 80 MHF .../100 MBF .../160 MBF .../250 MHF(S) .../400 MHF(S).../600 MUB..., 1650 MHS.... [800 ‘Valid for the control versions: PC 400 (plus) PC 4000 Mp cman ents INDEX 1, Manual operation. 1:1 Morse 12 Sat pte 13 Closing the mou 1.4 Opening of mould 1.5 Ejector (ptona). 1.6 Brashing and demeoling device on of 1.6.1 Move brushing device I ino operating postion 6.2 React brushing device | 1.7 jection 1.8 Retum (Ling) of jection unt. 119 Exod ning 1.10 Retrat defconnest die only srewiram injection uni) 1A Seip intake monitoring, 12S intake 1:13 Amomatic movement fo the starting porion 2, Automatic operation 21 Operating este 2.1.1, Closing a safety gate (anon. 2.12. Ejector on closing se rer. 2.13. Ejector on injocton side sour 2.14, Cental ejector rum, 2.15, Mould chosing 2.1.6, Nozae docking (nly ste am injection unit). 2.1.7 Injection 2.18. Valeaniation. 81 Degassing 24.9. Nozze retract (oly sre rm injestion ni). 21.10, Mould opening 2.11. Bjecoe of injesion si forward 12, Ejector of eosing side forward 13, Cental ejetor forward Brush 15. Opening of suet at 16, Cyete en 3. Monitoring and alarm function een “Tho following machine alr are possible 1h £0.04 ots oMephn 1. Manual operation In the mode maual operation all machine movements are initiated by depresing the respective push button on the contol panel. This allows the execution ofall settings roquted during mould change andthe cleaning ofthe machine 1.1 Motor start ‘To allow the movements in manual operation you have to release all emergeney-off keys the motor as to be started a the ey site has tobe switched to manual operation. nate “The safety gate ensures the safety ofthe operators Inthe basi version the machine i supplied with a manually operated safety pate, ‘The safety valve YS is activated (aydeulic closing sufty) via the safety cncut (safety gate closed). As an option the machine can be equipped with a pneumatically operated safety gate ‘The safety gate closes automatically, if a movement has to be performed on the machine (Pneumati valve YGC, not on the control unit) A second possibility of safety gate operation is given by opcrating the key "Front saety gate". With his step te safety gate remains closed ‘until the repeated operation ofthe key If during the closing operation the safety gate meets an obstacle, the opening movement is immediately initiated, an at the same time the alarm "Safety stip is ativated us Mp Closing the mould ‘The closing movement is conrlled by activation of the key "Mould closing " During this operation the following valves are controll Safety valve Ys. Scavenging valve ves Safety gate valve vac (irexistng) ‘Mould closing yee Mould elosing 1 yee (iFexisting) Preconditions for mould elosing: Emengency-off released + motor runing Safety circuit closed [No alarm (ony with manual operation) Ejector put into operating position imum mould height not reached Handling devices retracted (if existing) Brushing device reacted (if existing) ‘The closing speed is aijustable (Refer to use manual 14 Opening of mould effected by actuating the key ,Mould opening” During this operation the following valves are operated: Opening of the mol Safety valve Ys (refilling valve opens, YPR is deenerpized) Scavenging valve yes Safety gate valve yoc Gfexisting) Mould decompression yep Mould opening yoo Mould opening 1 YCOl (only with 400 t and 6001) Opening speed car beset om the Seren (soe user mal. Preconditions for mould opening: Emergency-off rleased + movor running Safety circuit closed "No alarm (only in the manual operation) Fp $000 « wis Mpa 5 Ejector (optional) [jection is effected by depressing the key ,Fjector movable plate forward or Ejector fixed plate forward” or "Cental ejector forward ‘During this operation the following valves are activated Safety valve YS Scavenging valve yes Safety gate valve yor (ifexisting) Ejector movable plate forward YME(YFE, YCE) (er ejector fixed plat forward ‘or central ejector forward) ‘The retum ofthe ejector is effected by depressing the keys ,Fjector movable plate return or Ejector fixed plate retuen” or "Centra ejector return ‘During this operation the following valves are activated: Safety valve YS. Scavenging valve vps Safety gate valve voc (dtexisting) Ejector movable plate retum —-YMR (YER, YCR) {oreector fixed plate return ‘or central ejector return) ‘The ejector speed respectively pressure has to be set on page Options”. The ejector displacement is adjusted with the proximity switches ,Bjector movable plac in operating position” and ,.jector movable plate retracted forthe hydraulic ejector ofthe closing side ‘and with the proximity switehes Ejector fixed plate in operating position and yFjector fixed plate retracted" forthe hydraulic ejector of the injection side. With ejector displacement ‘measuring (Option) the nominal value has to he determined en page ,Options". ‘The centalejoctr is equipped with fixed stroke of 100 mim, This stoke canbe limited only by stops in the mould. As an option the central ejector ean also be supplid witha displace- ment measuring (160-400 0. Preconditions forthe ejector: [Emergency-off released motor unig Safety gate closed (existing) ‘No alam (Only with manual operation) “Mold opened (only fr ejector forward) 1.6 Brushing and demoulding device on - off 1.6.1 Move brushing device 1 into operating position During this operation the following valves are activated: Move brush into operating position —-YBIL Brush blocking 1 YBLI After having operated the rotating key the rush blocking YBC 1 wil be released frst, After (0.5 seconds the movement valve YBI 1 is activated ‘When the switching contact “Brush in the mould area" has been reached, the brush motor stars. The motar is electrically controlled via 32 KI and 32 K2. 1.6.2 Retract brushing device 1 During this operation the following valves are activated: Revract brush 1 ‘YBO | Brush blocking YBL 1 ‘As soon asthe switching contact "Brush in the mould aca has been reached, the brush motor is shut down, Preconditions for brush moving into operating position and brush retracting: “Mould open [Emergency-off released + motor runing Safety circuit closed Bush inthe mould area Ejector ok for brush (moved into operating postion or retracted) FB a E00 vis Maplin LZ Injection Injection is effstedby depressing the key ajo. Daring this operation the following valves are activated: Scavenging valve VPS: Injection ¥IN Check valve injection unit YINI Injection speed is preset on page Injection" Preconditions for injestion: Emergeney-of released + motor euning No alarm (only with manual operation) ocr material intake closed 1.8 Return (Lifting) of injection unit Lifting ofthe injection units effected by depressing the key Injection uit return During ths operation the following valves are activated: Scavenging valve Yes. ‘Return of injection unit ¥IR Preconditions for return of injection unit: Emtergeney-off released + motor euning ‘No alazm (only with manual operation) ‘Door material intake elosed Fh £90800 us Maple rolled by depressing the Key Pxtruder running” (on the in (next to material intake), ‘The plasticizing process is c «contol pane or Extrude During this the following valves are activated: Scavenging valve ‘VPS Plasiizing Yel, Injection unit return (only with ,Retract injection une YR cleaning position) The dosing speed (Serew speed) is preset on the page plasticizing, The screw speed is electronically measured and indicated on the display Preconditions for extruder running: “Emergency-of released + motor ranning [No alm (only with manual operation) Injection pison in the pot (Dosing volume not reached) OR injection unit completely retracted. -screw/ram injection unit) During this the following valves are activated: Safety valve ys Scavenging valve yes Connect die YF “Move interlocking block into operation positon YIB, Proconditions for rotract die / connect dle: Emergoney-off released + motor runing Safety circuit closed LIM Strip intake monitoring ‘As an option the machine can be equipped with 2 strip inaks monitoring. ‘This monitoring device includes a roll equipped with an initiator giving impulses to the control during rotation, ‘This function must be cut in onthe sereen, and the coresponding time has to be determined sccordingly. If durin this time no impulse is given to the conc, the alarm yMatria feeding” is released. Fah csoso 6 5 Mp “10. 1.12 Strip intake “The machine can be delivered with a strip intake as optional equipment, (On this version the n rolls, terial sep i supplied to the intake opening via 2 eletically driven By the plasification the material strip is stretched, and a Timit swite is activated which sites om the roll moor ‘The motors switched off again after a period wich an be sot screen). 1.13 Automatic movement to the starting position ‘The stating position (basic postion) can be obtained automatically by depressing the key «Slating position” In this ease the eyele is stating withthe step "Mould opening" and runs off using this procedure the key ,Starting position” flashes, and no other movements can be performed. Ifthe starting postion is reached, the key, Starting position’ is illuminated. the stating position cannot be reached (e.g. the dosing volume has not been reached) the ‘lam Starting positon is activated [Normally this function is used afer interuption of an automatic eyele in order to put the ‘machine ito the stating positon. ‘Preconditions for automatic start of the basie position: Emergency-off released + motor eunaing No alarm Manin on Automatic operation Precondition for changing over ffom manual operation to automatic operation isthe starting positon (Lamp on the contol panel or indication of eventually missing conditions on the Aisplay), If the stating postion is not reached, the lamp ,Manual operation begias to flash when hanging overt automate operation, ‘The automatic operation is indicted by the signal amp , Automatic" Inthe automatic mode the machine performs «complete operating cycle after each activation of the key ,Cyce start If with processor control the function .Pully automatic” is switched {0 ON, the next automatic eyleis started immediately after the end of eyele (The key ,Cycle sar is not requited), during automatic operation you change over to manual operation, the avlomatic cycle interupted andthe machine is apain inthe manual mode (the lamp Automate” extinguishes, the lamp Manual operation ison). 2.1 Operating eyele The operating cyele can be ffeely determined within frreaching limits. But you have observe that the operating exele will always be closed with the stp Cycle end Further you have to enter the steps ,Mould closing", . Injection", ,Vuleanizing . Mould opening’ ino the cyele configuration ‘The automatic cycle shall be explained by means of the following configuration. Close safety gate (manually) jector closing side return Central ejetor return Hjector injection side return ‘Mould closing Injection Vuleanizing Mould opening [Ejector injection side forward [jector closing side forward Central ejetor forward Brush Open Cycle end sy gate emai 2 2 Closing of safety gate (manual itches over to the next ‘The safety gate is closed, The condition "Safety circuit is elosed”™ exee sep. Valve as an option: Closing of movable safety gate front side YGC Precondition for "Closing of safety gate Fmergeney-off released + motor running ‘Safety strip front side urs Valves: Seavenging valve yes Safety valve ys Closing of mobil safety gate on front side YGC Grexisting) Fjector movable plat return YMR Preconditions for Ejector om closing side return: Bmergeney-off releesed + motor running Safety circuit closed Brushes reacted ‘The Ejector on closing sido" is moved into operating positon withthe parameters set onthe processor contol, The initistor ,Ejector on closing side return (or if actual displacement value < nominal value for moved into operating postion with ejector displacement ‘measuring) switches to the next eyle ep. ‘oMapin 2.1.3. Ejector on injection side return Valves: Scavenging valve yes Safety valve ys Close movable safety gate on font side YGC Gfexisting) "jeetoe fixed plate forward ER Preconditions for .Ejector on injection side return Emergeney-off released + motor running Safety circuit closed Brushes retracted ‘The ,Fjector on injection side is moved ino operating positon with the parameters set in the processor congo. The initiator ,Fjector injection sie return (ori actual displacement value < nominal value for moved into operating position with ejetor displacement measuring) witches tothe next cycle step 21-4. Central ejector return Valves: Scavenging valve yes Safety valve ys Close movable salty gate on front side YCG (exiting) (Cental ejector retum vor Preconditions for ,Central ejector return Emergency-off eleased + motor ruaning Safety circuit closed Brushes retracted ‘he Central ciector" is moved into operating position with the parameters sot in the processor control. The initiator ,Centralejoctor return (or if actval displacement value > ‘ominal value for moved ito operating positon with ejector displacement measuring) ‘witches tothe next cycle step. as Mania oe 21S, Mould closing 2.5.1 Mould closing Valves: Safety valve ys Scavenging valve yes Closing of movable safety gate on font side YGC (Gtexsting) Mould closing yeo Mould closing 1 YCCI (only with 4008) Preconditions for Mould closing’: Ejector on closing side moved into operating position Ejector on injection side moved into operating position Cental ejector moved ito operating position Sing plate moved into operating position Emergency-off rleased-+ motor runing Safety circuit closed Minimum mould height not observed Brushes revacted ‘The closing unit moves up to the mould closed point atthe parameters set inthe processor control (usually 3 speed steps). 25.2 Closing of prefiling nave Valves: Safety valve ys. Scavenging valve yes ‘Close movable safety gute of font side YGC (texting) Preiling valve YPR Preconditions for closing of prefiling v Emergency-off released + motor running ‘The prefiling valve is actuted and switched to the next eye stp after an intemal ime delay. as oO Mapa ois: Valves: Safety valve ys Scavenging valve yes Profiling valve YR Close movable safety gate on fiont side YGC ‘Gtexisting) ‘Closing pressure yeu Preconditions for clamping pressure build-up : Mould eosed “Bmrgency-off released + motor running Safety eteuit closed ‘The mould is closed with high pressure. Subsequently switching onto the next eye step is effete. Valves: Safety valve ys Rinse valve yes oz docking ver Preconditions for nozzle docking: Emergency stop unlocked and motor inning ‘Material intake door elosed ‘The nozzle is docked atthe set pressure. The switeh “nozzle docked” switches tothe next cycle sep, Valves: Scavenging valve yes Injection vIn Nozzle docking ‘VIF (only erew ram injection wait) Preconditions for injection: -Emerzency-of released + motor running Door material intake is elosed [Nozzle docked (only serew ram injection unit) ‘The injection procedure (3- or S-stage speed profile) and the holding pressure (2stage pressure profile) are eifevted according to the sting in the processor conto, subsequently the vulcanizing time is started and switched over tothe next eyele step, FDA 60.80, M15 Mp 6. 2.18. Vuleanization ‘The vulcanizing time rans in this eyele step, When the time has elapsed changeover t the next step i flected 8.1 Degassing Inthe step vuleanizaton the function degassing ea be performed atthe same time. To ensure this the parameters number of strokes and delay have to be determined in the processor ccontrol accordingly. After elapsing of the delay time "Delay degassing” degassing is elected by: ~ Pressure reduetion in the main closing eylinder Valves: Sefety gate valve voc Scavenging valve yes Safety valve ys Decompression of mould yep ‘Maintaining the position vec ~ Opening of the mould (Stroke adjustable) Valves: Safer gate valve yac Scavenging valve yes Safety valve ys. “Mould decompression activated yep “Mould opeaing yoo. Mould opening! YCO11 on 4001 machines) ~ Mould closing with repeated clamping pressure build-up, Valves: Safety valve ys Scavenging valve yrs Safety gate valve yoo Pressure build-up yeu ‘This procedure is repeated unl the set number of deyassing operations has been reached, us oManin 0. | | 1.8.2 Plasifica After elapsing of the ,Dosing delay” plastcizing is effected. The ssrew driven by a hydraulic ‘motor feds the material into the injection chamber, The plasificaion is Finished at teaching the position .Dosing volume. In order to avoid that material flows out into the opened ‘mould, a material decompression will always be effected after the pastiiation, Valves: Scavenging valve ves Extader ning PL Back pressure BP ‘Return of injection unit 1 ‘YIR (only FIFO-njection unit) Preconditions for plasticizing Emergency stop unlocked and motor runing Dosing volume not reached "Nozze docked (only serew ram injection unit) retract (only screw ram it it) ys yes YB Preconditions for nora retract: Emergency stop unlocked and motor runing Injection unit door closed After reaching the postion “nozzle retracted” the cam switch switches to the next eye step 2.1.10, Mould opening 210.1 Mould decompression Valve Safety valve ys Scavenging valve yes Closing the movable safety gate on front side YOC ‘Mould decompression yoo. (ieexistng) Mold closing vee Preconditions for ,Mould decompression: Emergency-offrlensed + motor unig Safety circuit closed ‘The main closing cylinder is unloaded and the prefilling valve is opened. After an internal ‘ime delay changeover to the next eyele step i effected PHN {10800 evs oMapia, a8 10.2 Mould opening Valves: Safety valve ys. Scavenging valve yes Closing of movable safety gate on front side YGC Decompression of mould yoo Grexisting) ‘Mould opening yoo Mould opening t ‘YCO 1 (on 400 t machine) Preconditions for Mould opening*: Emergeney-off released + motor ruzning Safety circuit closed ‘The closing unt moves up to the mould open point at the parameters set in the processor ‘contro (uswally 3 speed steps). Subsequently changeover to the next eyee step is fete 2LI. Ejector of injection side forward Valves: Safey valve ys Seavenging valve yes Close movable safety gate on frontside——YGC exiting) Ejector fixed plate forward YrE Precondition for Ejector of injection side forward: Mould opened Emergency-off released + motor unning Safety circuit closed Brushes retracted ‘The eestor ofthe injection side is moved forward withthe parameters set nthe processor contra. The iniator , Ejector of injection side retracted (orf the actual displacement value > nominal value retracted with elector displacement measuring), switches over tothe next pele step. ‘oMapin oy. Scavenging valve yrs Closing of movable safety gate on font side YGC Uirexisting) Ejector movable plate forward YME Preconditions for ,Bjector of closing she forward Mould opened Emergency-off released + motor running Safety circuit closed Brosh retmcted ‘The ejector ofthe closing side is moved forward with the parameters set in the processor oni, The initiator Ejector of closing side retracted (or if the actual displacement value > nominal value retracted with ejector displacement measuring), changing over tothe next eyele step is effected, 13, Central ejector forward Valves: Safety valve ys Scavenging valve yes Closing of movable safety gate on front side YGC (ifexisting) Cental ejector forward Yee Preconditions for ,Central ejector forward ‘Mould opened [Emergency-off released + motor running Safety circuit closed Brushes retracted ‘The central ejector is moved forward with the parameters set in the progessor contol, The initiator Central ejector reacted (or i the actual displacement value > nominal value of retracted position with ejector dispacoment measuring), changing aver tothe next eycle step is effected. 14, Brush Valves: Brush 1 in operating position YBI (ith time delay 0,5 see after YBL. 1) Brush blocking BL When the switching contact "Brush 1 inthe mould area" is reached, the brash motor stars sunning ‘When the switching contact "Brush 1 inside” is reached, the valve YBI 1 euts offand YBO Is activate, ‘The brushing eycles set in the processor contel are performed. When the brush moves up far the fas time, the brush motor is switched off after aching the positon "Brush inthe mould Preconditions for moving into operating position and retracting ofthe brush: Mould open Emergeney-off released + motor runing Safety cect closed Brush inthe mould area [Becta ok forthe brash (moving into a out of operating position) 15. Opening of safety gate “The safety gate is opened manually (as an option pneumatically) 16, Cycle end ‘The automatic eyee is finished. Anew eye can be started by operating the key "Cele star” in the control panel Ifthe function "Fully automatic" is set to ON, the next eyele is started immediately. FB. 180.90. v1 Maplin 3. Monitoring and alarm function Jn case ofan alarm, the Hashing lamp ,General alam and the indicating lamp ia the key Alarm off are activated. Simultaneously, the respective alarm designation appeats on the Aisplay. After depressing the Key Alarm off, the general alarm is deactivated and the alarm designation remains on ,1* until the alarm is reset IF the reason for alarm has been liminated, th alarm designation will also be cleared on the display The following machine alarms are possible: Cause ‘Measures [Eliminate tho obstacle [Recool or change the of, The saftey gate meets an obstacle during the elasing Too high Oil temperstare check het exch [ou iter Contaminated [Change itr Cit Tevet Too low Refill oil chedk TorTealsh Ia Rubber sp Broken eed new stip [Vuleanization time) The machine cannot be opened [Cheek times, venting, exceeded after elapsing of the vulcaniza- |plasticizing and injection unit tion time, because venting, [lifting must be fished within injection unit iting or ‘the vuleanization time. plastcizing isnot finished EMPRGENCY-OFF | EMERGENCY-OFF setivaied_ [Release EMERGENCY. OFF Exceeding of cycle time | Machine cycle is longer than | Modity the nominal eyee ime] these ele time monitoring _Jon page production data. Exceeding oF injection [The injection proceduce Isis | Correct the nominal injestion time longer than the nominal ime. injection ine Sey (Monitoring of he Tinie switches of safety gate or safety [eat closes too slay ‘Door material iatake |The door on the injetion unit is not closed injection unit return are only possible with closed door. Say closing Fete monitoring ofthe [Check hydraulic safety closing safety closing valve reacts and wiring, check valve anston hf 90-800.¢ 15 Moin Alarm Cause Measures eating off The timer as cat ofthe | Modify the times ofthe tner eating on te running machine or cutoff the timer [Mould protection | The mould protection time was [Chock the mould, eventually exceeded increase the speed ,Closing slow" or Pressure mould pro- tection or ,.Time mould protection” Staring position cannot [The set ime provided for [Move to the taring position be reached automatic travelling into the fin the manval operation (dose stating position was exceeded eventually i the manval mode Min mould isialation height Tieight of mould isnot sufficient. The actual value of| the clamping unit has not reached the min, mould se an intermediate plate installation height. Temperature range One or more temperature zones [Chek the tolerance, cooling Jarcbeyond te tolerance. agent to hot, isnot yet, nated Batery Battery athe contol power [Change bation is unloaded Broken delcting Init voltage of detecting ole- | Check detecting element [clement nent isnot between 0 and omy. Quant reached Sct quay has boon reached [Clear plese counter or cut olf the stop a quantity reached Injection curves Tho st envelope curve was | Modify te envelope curve or Jexeceded or not reached at the cu off the alam or change the injection procedure injection parameters (Coniol cand The contol ca value is | Modify the flerance or eu of beyond the range of tolerance |e alarm Ace RaTaEHeRE[Natanseineal ies [ero ieee Wo elapsed Teating earent ing Fah Fanon « 915 Te healing current monitoring | Chock the power eonsumapion lot one temperature zone has of the temperature zones ocen actuated Manin “8. MAPLAN MAPLAN, MASCHINEN U. TECHN, ANLAGEN PLANUNGS- UND FERTIGUNGS-GES.M.B.H. OPERATING INSTRUCTION Injection mould machine: T (Top), B (Bottom), H (Horizontal) for the types: MI(HF 400/80 MT(B,ENF 750/160 MT(B,H)F 1500/250 MTF 150/300 MT(B.E)F 2500/40 MI(H)F 1500/600 MB(H)S 52001400 ‘MES 8600/400 MB(H)S 5200/650 MHS 8600/650 MB(H)S 5200/800 MHS 8600/800 MTF 2500/300M MT(B)S 2500/300M MTS 2500/300 MTF 4000/500M MIXB)S 5200/500M_ MBS 8600/500M ‘MTF 4000/800M MT(B)S 8600'800M INDEX |. SAFETY DIRECTION 2:TRANSPORT INSTRUCTIONS. 2.1, HORIZONTAL MACHINES: 22, VERTICAL MACHINES: ‘INSTALLATION AND FIRST SETTING INTO OPERATION. 3.1 OPERATION - 4. MACHINE ADJUSTMENT. 4.1 ABWUSIMENT OF THE PROPORTIONAL HYDRADLICS. {42 TeweRarure contro “2 442. Injection ait ' 2 ‘42.1.1 Selection of mater preening empeatne ~ i 422. Mould (entng plates) ve voc 14253 Hygauli ol : 1 5. MOUNTING OF THE MOULD . 6.DAILY START-UP OF THE MACHIN 7. SHUTDOWN OF THE MACHINE... 8. CLEANING OF THE VALVESEAT. 8.1 oxLv FIFO. 7 12.1 INIECTION CHAMBER / PISTON 30 00cm oeque vale. i 2.2 Valve seat 401 16000cem torgue value . 8 182 TORQUE VALNELISt it 9, CLEANING OF THE CHECK VALVE. 9.1 ONLY FOR SCREW PISTON INJECTION UNIT.. - 20 BA cok £5, $0400 (m)_e82 © Msplan 1. Safety directions ‘This rubber injection moulding machine hasbeen designed for processing elastomers and ‘therefore its application i limited to the production ofrubher shaped castings. The owner {operating authority) ofthe machine is responsible fr the appropriate use ofthe machine. ‘The owner has to care that exclusively trained personnel attends the machine. The safety ‘echnical systems incorporated in the machine ensure a safe operation without danger, only unde the condition tha the machine is operated in accordance with its application. ‘The owners responsible, tha forthe maintenance or repr there will be used exclusively spare parts from the manufacturer (MAPLAN) or according tothe manufsetrer’s specification (refer to spare part is). ‘When processing certain clasiomers, unhealthy gases, vapors and dusts may be released during the vulcanization. The machine owner should clarify ths problem withthe raw ‘material supplier and eventually provide an exhaust facility in the operating room, ‘During the production process both heating plates and the mould are heated up at temperaturs between 150° and 210° C standard insulating plats respectively 250° C special insulating plats, The plesteizing unit and the injection chamber reach temperatures between 70° and 100°C during operation. As shielding of these components {is technically not possible, the machine oye bas to care hat he operators andthe personnel responsible for maintenance have been tained accordingly “The maximum admissible temperature ofthe plasticizing unit is 130°C (when using a chilling unit). I this temperature is exceeded, the plasticizing unit willbe damaged. The operating athorty has to check the quality ofthe hoe ines in gular interval, at least every 8 weeks. Iany damages have been found, the respective hose lines have tobe ‘replaced, Thi also apis to al lectial cables on the machine. In this case a visual inspection will be satisfactory nthe machine control cabinet ax well vn the terminal hoses mounted on the machine Is provided electrical equipment wih voliges bel highly dangerous. vbh_ 6s_a0s00_(w)_e_v32 © Maplan Before opening the machine control cabinet as wells the terminal boxes shut down the ‘machine via the main switch. Any kind of maintenance or handling maybe performed exclusively by competent personnel Cary out maintenance work on the hydraulic system only onthe shut-down machine, When switching off the machine, it hast be in its basi postion otherwise thee ean stil be some pressure the hydraulic system. During operation the hydraulic oli a pressure of 210 bar (280 bar onthe C-iame machine, 265 baron the machine MTF 15001300). The opening of the hydraulic system during machine operation is dangerous and not allowed, Mainicnance work onthe eilling unit may be performed only on the shut-down machine, ‘The thermal Hud in the chilling unit and in the cooling circuit (hoses, .) ean reach temperatures up fo about 130°C and therefore you have to he especially careful, BA_vboh_fs_90400_(n)_¢032 © Maplan 2.Transport instructions The machines are tansported wo the customer as following 2.1. Horizontal machines: _MILE 400/80, MTF 750/160, MIF 15001250, MBF 15001400, MES 200/400, _MIIS 8600/400, MS 52001650, MS 800/680, MHS 5200/800, MES 8600/800, MF 25007400 “The machines are supplied only with separate control cabine, “The packing modes areas following 3) without skid, dizetly mounted on truck (control cabinet as well) b) skid mounted (control cabinet as wel) {©} orcontsiner in open top” design. The machine ean belied from top out of the container by means ofa crane, 2.2, Vertical machines: ETF 400780 ‘The machine is mounted on a skid either in vertical or horizontal positon, separated from the control cabinet, In some cases (upon customer’ request, for container anspor.) the injection units disassembled fom the machine and mounted onthe skid ofthe machine, M(B) 750/160, MT(B)F 15007250, MTF 15001300, MTP 2500/4 [MBF 1500/400,METF 2500/300M, MTF 250/300, MT(I)S 25003001, [MBS 5200/400MTS 2500/300, MTF 4000/S00M, MT(B)S 5200/500M, "MBS #00/S00N “Those machines are always separated fom the contol cabinet and the hy ‘tansported in horizontal postion ona ski uli unit and ‘Qn machines with serewiram piston injection units this unit wil also be separately packed for delivery! MTF 1500/600, NIT 4000/8001 ‘This machine i always supplied with seperated control cabinet as well as hydraulic unit! Aitionallythe machine is divided into two main components for transport. The clamp ‘uit without the fixed plate ofthe injection side is provided with a makeshift construction {ior tanspot an supplied in horizontal position ona skid, the fxed plate ofthe injection side including the injection unit andthe hydraulic ejector i existing -are packed ‘separately fr delivery. BA toh fe_a08 (o)_ea2 © Maplan [MBS 200/800, MBS 52001680, MBS 5200/800M ‘These machines are always separate from the switch box and from the hydraulic equipment (pump se, tank, control block), being mounted on aeradle. The machine casing, the heating platens and any optional equipment sliding plate, hydraulic bar ejector ete.) are supplied separately packaged, ‘When unloading the machine or the machine components pay attention to the labels (transport instructions) on the packing or directly onthe machine (in ease of transport by {nuck). These instructions have to be observed carefully, a in ease of improper taneport the machine ean be damaged, or danger of life ean resul forthe forwarder. Transport of the ‘machine or machine components is reserved exclusively to specialized personnel MI The transport of the machine as wel a the machine components ie reserved exclusively to competent personnel. BA_voh fs_an-00_(m)_es32 © Maplan 3.Jnstallation and first setting into operation [Normally the machine andthe control cabinet are supplied separately. 1, Position the machine on a horizontal slid floor (il-resistant oor of workshop) in sccordance withthe enclosed installation plan ill he hydraulic tank with the hydauli (Use a filter fo filing, 3. Comnect the cooling water supply and return line. Connecting dimensions on the ‘chines vp to 80 tons clamping force: 2 x 3/8" interal thread; connections on al machines with a clasping force above 80 fons: Lx 1/2" ineral thread on the supply Tine and 1x 3/4 cera thread onthe ream line. cil specified inthe maintenance instctions 4. Connect the compressed inteal thread supply. Connecting dimension onthe machine 1x 38 45. Fill of coolant 5.1 FIFO-Injetion unit Fill he chilling unit fr the injection chamber an plastiizing eyindoe with the thermal uid spoctied in the maintenance instmctions (Use filter for filing! 52 Serew Ram injection unit (optional FUFO injetion wnt) the machine is equipped with a srew ram injection unit (optional FIEO injection anit) the both single circuit temperature devices for plastcizing and nozzle cylinder have to be filed with a specify thermo oil respectively water glycol mixture (use a food filter! 6, Provide the power supply to the main switch tobe done only by skilled personnel BA tbh fs anan_m_e v32° © Maplan ‘The following work will be performed by MAPLAN service department: “The comection between the machine andthe contol cabinet 2, The connections for the hydraulic ol, cooling water and dhermal fluid on the machine will be inspected and tightened if necessary. (Due to the vibrations during transport all comieetions being not sufficiently secured can get loose). 3. Comteetion of pump moter. Plug connections between the machine nd the control cabinet willbe established ATTENTION: Inposiion "On" the man switch interlocks the contol cabinet door. Opening or loxing by force ofthe conrleabine dor at "On" pasion wil desry the mun sich, 5, Check ofthe wiring, 6. Closing of control cabinet and switching on of main switch 7. Check of the sense of rotation of the tempering nit motor (row marker) In case of ‘wrong sense of rotation the wies wll be chang! 5. The Push-button "Pump on” has t© be operated and the senso of rotation of the main ‘motor will be checked. The motor fan has to rotate clockwise (arow market) when ooking onto the fan. Incase of wrong sense the wiring has to be comected. Under no «ircumstanees must you run the motor anti-clockwise, This woul eause the destruction ‘ofthe hydulic pump, 9. Make the pump run for several minutes and check the oil level. At the first seting into ‘operation air may be included in the system during a certain period, therefore pump ‘us not be loaded immesiately and te system has t be vented, 10:The same procedure is applicable forthe cooling nivheating uni, BA_ebh_ Fs $0-800_(@) e032 © Maplan “10 ‘ 3.1 Operation ‘Check ll movements ofthe machine during manual operation (plo lamp “Manual” is not illuminated eset EMERGENCY OFF kes), 'Ajetky ovement ofthe eylinders points oat inched in the system which will ‘Ssappeae alter sever minutes. Check l tei fr leaks. ATTENTION: ‘De not start an antomatc cycle without a mould ora distance pivce which x no exceeding the ‘minimum mold mounting dimension BA vok f_s0am0 (mje 82 ©Maplan ou 4__Machine adjustment Setting of the machine is divided into the basie setting which ie carried out inthe works of ‘he manufacturer and which bas not tobe modified by the customer, and the setting which is dependent on the produet and mould cated out by the eustomer. ‘When setting product and mould dependent values, make sur that setting i always governed bythe principle of , Safety fist", in case of dou, always stat with lower pressures and lower speeds rule out positively any damage to the mold ar tothe ‘machine. 414A t of the proportional hydraulics ‘The seting ofthe proportional hydraulis is made in the works and shall not be modified by the customer, 4.2 Temperature 1 ‘Tempering ofthe injection unit is obtained in three ones, whereas the material feeding is clectrically heated, the barel and injection chamber are cooled bya fluid ciruit, When the tempering unt is switefe off, the barrel and the injection unit are continuously cooled. ‘The heat transfer fluid is maintained at a constant temperature by means of a thermostat and an luid-water hea exchanger. For special rubber compounds and for operating the machine with cold runner block we recommend a heating unit for heating the injection unit (Option). of material preheat temperature mainly depends onthe characteristics ofthe rubber to be processed 8). Usethe back pressure control Adjust the temperature ofthe nozzle and the bare atthe desired val; for increasing the actual temperature inrease the back pressure, I the desired back pressure hasbeen reached andthe temperature is tl too low, you ean inrease the Screw spool for obaining a further ris a temperature, 1B) Increase the back pressure during platcizing step by step until the required temperature has been reached, ©) Ifehe temperature has farther tobe increased inspite of reaching the maximum back pressure, ou have fo increase the temperature ofthe serew feeding Zone, BA_ebth_fs_$0-890_(m)_e¢ 32 ©Maplan 212 Mould (Heating plates ‘Two electrically heated plates ae provided for thermoregulation of the mould. In order to achieve a uniform heat distrbation, heating must always tke place with the mould being closed. “The maximum admissible operating temperature wh standard insulting plots fs 210°C In nse of higher aperaing temperatures, amoulfeation wth spect using plates has to be perform (mas. 250°. 42.3 Hydraulic oit ‘The temperature ofthe hydraulic ol is indicated on a thermometer arranged onthe tank. | Coolings obtained by aheat exchanger with adjustable thermostat valve, The setting of| I the thermostat valve shal give anol temperature of appeox. 40° C (105° F) for continuous operation [ BA_ebb ts s0400_(m)¢ 32 © Maplan “B- 3.__Mounting of the mould 5.1 Check nozzle diameter and rebore if necessary (nozzle bore diameter must be at least 0.5 mm smaller than the mould bore). 5.11 Paton the nozzle of FIFO injection nit taking nto consideration the corre position ofthe cup spring (see mounting situation). Do no use a tel hammert 5.1.2 The contet position of the nozzle (serew ram injetion unit) i set by Maplan. By ‘any leakage on the nozzle there can be adjust in docked postion by remove and repeated tighten ofthe fastening oF the injection unit onthe tilting bracket. 52. Check centering dimension and wall ‘mould height is met), ikness of mould (making sur that minimum 5.3. Position mould, close the machine and flange both halves ofthe mould. Heat up the mould. 5.3.1 With the hydromechanie clamping unit adapt the threaded spindle ofthe mould height adjustment tothe effective mould height (Mechanical adjustment, hydraulic. adjustment at an option). 54 Activate selector switch ,Fxtrader un off and let the machine run some full cycles in the Automatic mode", while carrying out fine adjustment of pressures, speeds and times. 5.5 Close the mould and check mould temperature. When mould temperature has reached the desired value, production may be started BA_ebh fs 40-000_¢m)_e.v32 © Maplan “Me 6.__Daily start-up of the machine 1. Open the water and air connection 2, Cut inthe main site 5. Actuate the switch "Heat on" and heat the mould I 3a. When using a time switch for heating the mould make sure that the evoling ‘water inlet will be opened. 4. Actuate the key "Pump on". 5. Cleaning ofthe injection unit 5.) FIFO: Iithas not yet been done at the last operation, ret injection piston (se job instruction "Cleaning af the valve sea”) clean the sere in ‘his position by using Sesh mitral, The material his to low out through ll 3 ‘openings of passage. Ifnecessary dismount the ijetion piston and clean it 5.2 Sorew piston injection unt: Disconneet the nozzle until the cleaning position has been reached. Alternately switch to Seren rotation and .Jyfection* until the remaining material has been ejected. IPnecessary separate the plasticizing unit fom the nozzle eyliner and clean the check valve, | 5. Oporate the key “yjecton" until the injection unit isin operating position. 6. At opened mould operate alematvely "Serew rotation" and "Unjection” for cleaning the nozzle and the sproe runner 17. Close the mould, 8. Afer reaching the operating temperature put the machine into stat position for "Automatic operation". 9, Stat material feeding (Actuate "Serew rovation” until the dosing volume has been reached) 10,Clean the mould Select “Automatic operation”, Sarthe exele BA cbh_ fs $0800 (a) e982 © Maplan ots 7.__Shut down of the machine 1. Before the lst shot actuate the optional function “Screw rotation off. 2, Actuate the key "Manual" The lamp “Aulomatie operation" will extinguish and the machine finely stops at "Manual. 3. Clean the mould carey 4. Close the mould 51 FIFO: Retrac the injection unit, clean the injection piston (se job instruction "Cleaning of the valve seat), operate the key "Serew rotation" until no material wil come out from the njetion cylinder. 5.2 Serew piston infection wnt: Disconnect the nozzle until the cleaning postion has been reached. Altemately stitch to Serew rotation’ and nection” until the remaining material has been jected. IFnecessury separate the plastcizing unt from the nozzle eylinder and clean the chock valve 6. Shutoff the heating and the pump. ATTENTION: When wing atime switch "Last running «chilling nit, the cooling wate inet has to be pene BA_ebh fe oo) 2.2 Malan -16- Cleaning of the valve seat 8.1 only FIFO ‘This instruction sheet describes the procedure to tighten valve seat, injetion chambers and injection pistons on plasticising cylinders. ‘Valve seats, injection chambers, injection pistons and plasticsing cylinders are made of ‘neat weated alloyed steels, which have a tendency to seize together (cold bonding) when are not property handled as described below 1, Clean the threads of both pats eaeflly. 2. Cany outa visual examination to check for any signs of damage 4. Te sealing surfaces have tobe clean and fee of damages, ‘4 as slightly the total length ofthe extemal and interal threads with Krytox GPL. 206 (by means ofa brush) Adention tse Krploe GPL 206 (X0704210)! 5. Iemust be easily possible to fx the valve seas et. to the mechanical stop (sealing surface) by hand, 6, Tighten the serews with the torgue wrench aecoring to the torque value list! BA ebb ts_a0-00 (a) e x42 © Maplan “0 BA_ebh_ f_f0-890_(a)_e_ 42 ete em) © Mapian ote 8.2 Torque value list “The selection of the comet torque wrench is of utmost importance! ‘The following list informs on the sizeof torque wrench tobe seleted fore respective

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