manual arburg

ARBURG GmbH + Co KG Postfach 11 09 72286 Lossburg Tel.: +49 (0) 74 46 33-0 Fax: +49 (0) 74 46 33 33 65 http://www.arburg.com e-mail: [email protected]

Operating manual for machine no. 207185

Thermofisher Scientific FSP BioLife Sciences Group

570 C 2000 - 800

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Preface / Safety Instructions

Preface

Additional information for USA, Canada

Safety instructions

Personal protective equipment

Transport and operating conditions

1 Introduction

1.1 Getting to know your ALLROUNDER

1.1.1 Technical data ALLROUNDER 570 C

1.1.2 Dimensions for mould installation / ejector connections

1.1.3 Mould weights

1.1.4 Machine transport

1.1.5 Machine installation

1.1.6 Cooling water and pneumatic connections

1.1.7 Electrical connections

1.1.8 Filling the hydraulic oil

1.1.9 Checking the direction of rotation of the pump motor

1.1.10 Setting the nozzle centre

1.1.11 Noise emission

1.2 Inspecting the safety devices

1.2.1 Overview of the safety devices on the ALLROUNDER 470 C, 570 C

1.2.2 Inspecting the safety devices on the clamping unit

1.2.3 Inspecting the safety devices on the injection unit

1.2.4 Overview of the switch designations of safety devices ALLROUNDER 470 C, 570 C

1.2.5 Inspecting the hoses

1.2.6 Replacement of parts after natural ageing

1.2.7 Safety markings

1.2.8 Position of the safety markings - ALLROUNDER CENTEX

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1.2.9 Inspecting the viewing panels

1.2.11 Inspection of screw-in fixing points for hoisting gear

1.3 General information on the SELOGICA controller

1.3.1 Modular structure of the SELOGICA controller

1.3.2 Software packages

1.3.3 Introduction to the screen layout

1.3.4 The status lines

1.3.5 Navigation mode and navigation level

1.3.6 The direct access keys

1.3.7 The special keys

1.3.8 The editing box

1.3.9 The parameter panel

1.3.10 The navigation levels

1.4 Overview of the operating elements

1.4.1 The most important operating elements and their functions

1.4.5 The operating panels

1.5 Accessories and machine sizes

1.5.1 Available accessories and optional equipment

1.6.3 Cycle time diagram

2 Production sequence, production / order control

2.1 Basic information on the production sequence

2.3 Extended production sequences

2.3.1 Basic sequence

2.3.2 Inserting symbols in the sequence

2.3.3 Erasing symbols

2.3.4 Moving symbols

2.3.5 Changing the start condition, switching over the drive

2.3.6 Programming examples of various production cycles

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2.4 Markings in the sequence

2.4.1 Dry cycle / automatic cycle

2.5 Data input

2.5.1 Inputting production data

2.5.2 Inputting mould data

2.5.3 Changing the units

2.6 Order control, production control

2.6.1 Inputting order data

2.6.2 Operating mode selection

2.6.3 Automatic switch-on/off

2.6.4 Sequences for start-up and shut-down

2.6.5 Order change

3 Machine movements

3.1 Machine movements

3.1.1 Parameter input and colour codes

3.1.2 Direction of movement in the graphical displays

3.2 Parameter input for machine movements

3.2.1 Options for selecting parameter panels

3.2.2 Basic information on parameter panels

3.2.3 Parameters for mould movements

3.2.4 Parameters for ejector movements

3.2.5 Parameters for nozzle movements

4 Temperatures, plasticizing process and part formation

4.1 Temperature settings for the injection unit

4.1.1 Recommended values for nozzle and cylinder temperatures

4.1.2 Temperature settings for the nozzle and cylinder heating

4.1.3 Cylinder cooling, programmable

4.2 Mould temperature control settings

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4.2.1 Mould cooling, manually adjustable

4.3 Nominal value control of cylinder and mould temperature

4.5 Plasticizing process

4.5.1 Dosage

4.5.3 Diagram: stroke volume / screw stroke injection unit 800 (15.3 oz

4.5.4 Decompression

4.6 Moulded part formation

4.6.1 Options for moulded part formation

4.6.2 Injection

4.6.3 Holding pressure

4.6.4 Remaining cooling time

5 Production control

5.1 Quality assurance

5.1.1 General information on quality assurance

5.1.2 Configuration of the monitoring graphics

5.1.3 Displaying the monitoring charts

5.1.4 Quality control and quality monitoring

5.3.2 Freely configurable pages

5.4 Monitoring functions

5.4.1 Monitoring off in set-up operating mode

5.4.2 Monitoring functions of machine, mould and injection unit

5.4.3 Monitoring functions

5.4.4 Mould position monitoring

5.4.5 End position monitoring via stroke marker

5.5 Printer

5.5.1 Types of printer

5.5.2 Printer connection

5.5.3 Printer configuration

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5.5.5 Configuration of documentation (printing or saving data

5.5.6 Archiving parameter panels and sequences, printing hard copies

6 Data set handling

6.1 Editing level and program designations

6.2 Program administration

6.2.1 Data memory

6.2.2 Program administration

7 Working with the machine

7.1 Setting into Operation

7.1.1 Inspections when installing the machine and during initial setting into operation

7.1.2 Switching on the machine

7.1.3 Mould installation ALLROUNDER 470/520/570 C

7.1.4 Zeroing the stroke measuring systems

7.1.5 Starting up the machine

7.2 Change of material, end of production

7.2.1 Important information on various plastics

7.2.2 Adjustment values and processing information for injection moulding materials

7.2.4 End of production, stopping the machine

7.4.3 User authorisation with transponder cards

7.5.6 Safety instructions for horizontal parting line injection

8 What to do in the case of malfunctions

8.1 Diagnosis

8.1.1 Valves / switches

8.2 Alarm functions

8.2.1 Alarms parameter panels and alarm functions

8.2.2 Alarm sequence

9 Cleaning and maintenance work

9.1 Cleaning the plasticizing cylinder, screw and nozzle

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9.1.1 Removing the injection unit

9.1.2 Swivelling the injection unit

9.1.3 Cleaning the plasticizing cylinder and screw with a cleaning agent

9.1.4 Nozzle removal, cleaning and installation injection unit 800 (15.3 oz

9.1.5 Removing, cleaning and reinstalling the screw, injection unit 800 (15.3 oz

9.2 Changing the screw tips

9.2.1 Screw tips

9.2.2 Tools necessary for changing the nozzle tips

9.2.3 Installing / removing the screw tips

9.4 Changing the plasticizing cylinder

9.4.1 Changing the cylinder, injection unit 800 (15.3 oz

9.4.3 Reinstalling the cylinder after it has been dismantled

9.5 Installing the thermocouples

9.5.1 Replacing the thermocouples on the plasticizing cylinder, injection unit 800 (15.3 oz

9.5.2 Exchanging the thermocouples on the nozzle, injection unit 800 (15.3 oz

9.6 Changing the heating elements

9.6.1 Changing the heating elements, injection unit 800 (15.3 oz

9.6.2 Changing the nozzle heating band, injection unit 800 (15.3 oz

9.7 External heating-up of the cylinder module

9.8 Maintenance and inspection work

9.8.1 Maintenance schedule

9.8.2 Oil change, inspection of toothed ring

9.8.3 Maintenance of the oil filter / oil cooler

9.8.4 Venting the hydraulic system

9.8.6 Maintenance and repair work on the hydraulic system

9.8.9 Pressure settings

9.9 Hydraulic oils and lubricants

9.10 Environmental protection measures

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9.10.2 Gaseous materials / vapours

9.10.3 Disposal of used oils and lubricants

10 Graphical recording and measuring systems

10.1 Graphics - nominal/actual values

10.1.1 Configuration of graphics

10.1.2 Recording the starting point

10.1.3 Setting the graphics

10.1.4 Graphics display

10.2 Measuring systems

10.2.1 Measuring systems of the SELOGICA direct controller

10.2.2 Connecting and configurating the measuring system

10.2.3 Measuring the mould cavity pressure

10.2.4 External switch-over devices

10.2.5 Measuring system for thermocouples

10.2.6 General measuring system

11 In/outputs

11.2 Programmable outputs

11.2.1 Function of the programmable outputs

11.2.2 Start and end conditions for programmable outputs

11.2.3 Linking and repeating outputs

11.2.4 Movement stages and output active in end position

11.2.5 Outputs non-cyclic, alternating

11.2.6 Starting outputs as a stroke-dependent function

11.2.7 Additional functions for outputs

11.2.8 Parameters for programmable outputs

11.2.9 Monitoring

14 Part removal

14.2 EUROMAP 67 interface for robot system

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14.2.1 General information on the interface

14.2.2 Connection between injection moulding machine and robot system

14.2.3 Pin assignment

14.2.4 Activating the robot system

14.2.5 Selecting the operating mode of the robot system

14.2.6 Inputting parameters for the robot system

14.2.7 Connecting a robot system, function check

14.2.8 Signal transfer, EUROMAP 67 interface

14.2.9 EUROMAP 12 adapter

14.3.3 Mould blow device

17 Software options / process technology

17.8 Production protocol

17.8.1 Parameter selection for the production protocol

17.8.2 Protocol (logging

17.8.3 Random sample selection

17.8.4 Production protocol

17.8.5 Protocol graphics

Important information

ARBURG subsidiaries and agencies

Important ARBURG addresses

Tell us your opinion

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Preface / Safety Instructions..\

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Preface

The purpose of this document This document serves as an introduction to the operation of your ALLROUNDER machine.

It is designed to simplify the process of getting to know the machine and allow you to fully benefit from its possibilities of application.

This operating manual contains important information to ensure safe, efficient and economic operation of the machine. Observing this infor-mation helps to avoid any dangers of personal injury, reduce repair costs and machine down-time and to increase the reliability and life- span of the machine.

This operating manual is to be supplemented by any additional safety regulations for the prevention of accidents and for environmental protection valid in your particular country.

The operating manual must always be at hand at the place where the machine is operating.

The operating manual must be read and the information contained in it applied by every person engaged in the following kind of work with or on the machine e.g.

operationincluding set-up, troubleshooting in the course of operation, removal of production waste, cleaning and the disposal of operating and processing aids.

maintenance (servicing, inspection, repair work) and/or

transport

In addition to the operating instructions and mandatory rules and regulations for the prevention of accidents and environmental pollution valid in the country and place of application of the machine, the generally recognized regulations for safe and correct operation particular to this field of technology are also to be observed.

2006 ARBURG GmbH + Co KG, Technical Documentation, D-72290 Lossburg, Tel. +49 (0)7446 / 33-0

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Contents of the document The machine is briefly introduced and its operating elements explained. Connection and installation of the machine is also shown. The possible functions are clarified with the aid of parameter panels.

Application examples and data suggestions are not included. One cannot learn the processes of injection moulding with this document.

The optimal application of the machine can be learned by following the respective machine set-up course.

The last page of this document has been reserved for you. Please complete these few lines with Your Comments.

Some chapters are compiled as an autonomous document and are only included if the machine comprises the respective equipment.

Layout of the operating manual This operating manual has a loose leaf system layout which is comprised of individual chapters. Any sections or even entire chapters which are not relevant to this machine type are therefore omitted.

On the other hand, some options, accessories and parameters may be described in the operating manual which are not standard equipment.

The pages are numbered within each section in order to speed up cross referencing.

All ARBURG registered trade marks are written in capital letters, e.g. ALLROUNDER.

Diagrams, dimensions, weights All diagrams, dimensions, weights and descriptions in this document are solely related to a possible combination of equipment features for this machine type. The appearance, function, dimensions and weights of your individually configured machine may well differ from these specifications.

Before starting any work for which you depend on precise specifica-tions, please contact us at ARBURG and ask for the data/drawings relating to your particular machine type.

The technical data correspond to the level at the time of going to print. In the interest of continual further development, we reserve the right to make modifications.

2006 ARBURG GmbH + Co KG, Technical Documentation, D-72290 Lossburg, Tel. +49 (0)7446 / 33-0

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Additional information for USA, Canada..\

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S A F E T YI N S T R U C T I O N S The working space in front of the control cabinet of the machine

must be at least 750 mm (2 1/2 ft) or more. (See illustration above).

The specified working space is to be kept free at all times and is not to be used e.g. as storage space.

The working space in front of the control cabinet must be freely accessible from at least one side.

When normally enclosed live parts are exposed for inspection or servicing purposes, the working space must be suitably safeguarded if it is in a passageway or general open space.

The regulations of NFPA 79 also apply.

( GB

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Locks on the control cabinet doors

The doors of the control cabinets are locked.

Opening the doors is only possible when the main switch has been switched off and the door in which the main switch is integrated has been opened.When the door with the main switch is closed, all other doors lock automatically on closing.

Opening the control cabinet doors

Switch off the main switch

Open the locks at the top and bottom of the control cabinet doors by inserting a two-way key (1) into the lock (2) and turning it 1/4 revolution to the right or left, depending on the locking position.

Open the door.

The locking plate (3) is moved out and releases the rod (5) which is turned by a tension spring (4)

All other control cabinet doors can be opened.

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Safety instructions

Warnings and symbols In this operating manual the following headings and symbols are used for particularly important information:

I M P O R T A N T

The text in these boxes contains instructions regarding the efficient operation of the machine, in particular precautionary measures to prevent damage to the machine.

S A F E T Y I N S T R U C T I O N S The text in these boxes contains information relating to your

personal safety or the prevention of machine damage. Observe these instructions and proceed very carefully.

Other symbols Three further symbols are also frequently used in this operating manual.

Symbol Explanation enumeration: identifies a list of items action: requires the machine operator to act reaction: identifies the reaction of the machine/controller to

an action

( TB

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General principles; designated use of the machine

The machine has been built in accordance with state of the art standards and recognized safety regulations. Nevertheless, its use may constitute a risk to life and limb of the user or third parties, or cause damage to the handling device/machine or other material property.

The machine must only be used in technically perfect condition and in accordance with its designated use and the instructions specified in the operating manual, by persons aware of its potential dangers and the safety regulations. Any functional disorders, especially those affecting the safety of the machine, must be rectified immediately.

The machine is designed exclusively for the processing of injection-mouldable materials in accordance with the data provided by the material supplier. Using the machine for purposes other than those specified e.g. using the machine as a press or for processing non-injection-mouldable materials or disassembling the machine and using the component parts for other purposes is considered contrary to its designated use. ARBURG cannot be held liable for any damage resulting from such misuse. The risk of such misuse lies entirely with the user.

Operating the machine within the limits of its designated use also involves complying with the instructions specified in the operating manual and the inspection and maintenance instructions.

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Organisational measures The operating manual and the short operating manual(s) must always be at hand at the place of work of the machine.

In addition to the operating instructions, the user must observe all other generally applicable legal regulations relevant to accident prevention and environmental protection and instruct other persons involved accordingly. Such obligations also apply for example to the handling of hazardous substances and to the issuing and/or wearing of personal protective equipment.

The operating instructions must be supplemented by additional instructions from the employer (including supervisory and reporting duties) covering the companys own particular facilities, e.g. in regard to work organization, work sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the operating instructions and in particular the safety instructions before beginning work. Reading the instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine e.g. for setting-up, conversion or maintenance work.

Check - from time to time - whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to the risks and safety factors involved.

Use personal protective equipment/clothing wherever required by the circumstances or by law, especially when working with hot injection moulding materials.

Observe all safety instructions and warnings attached to the machine.

Ensure that safety instructions and warnings on the machine are complete and perfectly legible.

In the event that safety-relevant changes are noticed on the machine or in its operational behaviour, stop the machine immedi-ately and report the malfunction to the competent authority/person.

Never make modifications, additions or conversions to the handling device which might affect its safety without ARBURGs written approval. This applies also to the installation and adjustment of safety devices and valves as well as to welding or other work on load-bearing elements.

If additional devices approved by ARBURG are subsequently removed, the original protective safety panels/devices must be reinstalled.

Spare parts must comply with the technical requirements specified by ARBURG. This is always guaranteed with original spare parts.

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Do not carry out program changes (software) to the programmable control systems, unless specifically permitted.

Replace hydraulic hoses within stipulated or adequate intervals even if no safety-relevant defects are apparent.

Adhere to the prescribed schedule and intervals specified in the operating manual for routine checks and inspections.

For the execution of maintenance work, it is essential to use only workshop equipment especially adapted to the task on hand.

Screws and nuts which are sealed with red sealing lacquer must not be re-adjusted or removed. The safety-relevant functioning or setting of the part could no longer be guaranteed.

For material refilling and all other overhead work on the machine, a suitable climbing aid is necessary: e.g. platform lift, safe ladder.

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Selection and qualification of personnel - fundamental responsibilities

All work on the machine must be executed by reliable personnel only.

Engage only trained or instructed staff; clearly define the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Do not allow persons under training / instruction or persons taking part in a general training course to work on or with the device/machine without permanent supervision by an experienced person.

Work on electrical equipment of the machine must only be carried out by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on gas-engineered equipment (pressure accumulators) is only to be carried out by especially trained personnel.

Work on hydraulic devices is only to be carried out by personnel with skilled knowledge and experience:

Safety instructions for specific operational phases standard operation

Refrain from carrying out any operations that might be prejudicial to safety.

Take all necessary precautions to ensure that the machine is operated only in a safe and correctly functioning state! Only operate the machine if all protective and safety-orientated devices, such as removable safety panels/switches/stops and emergency-stop equipment are in place, fully functional and activated.

Inspect the machine regularly for visible damage and defects. Report any changes (including changes in its operational behaviour) to the competent authority/person immediately. If necessary, stop the machine and inhibit all functions.

In the event of a malfunction, stop the device/machine immediately and inhibit all functions. Have any defects rectified immediately.

Observe start-up and shut-down procedures, inspection and monitoring displays in accordance with the operating manual.

Before starting up / actuating the machine, ensure that nobody is at risk by its functions or movements.

For the overhead task of refilling the material hopper suitable climbing aids must be used that comply with safety regulations. The same applies when connecting and disconnecting supply lines or pipes of conveyer appliances. Switch off machine before refilling the hopper.

For all work to be carried out on the machine, in particular work inside the protective safeguards or work on the plasticizing unit, always switch off the main switch first and secure it against reacti-vation.

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Non-routine work in conjunction with the utilization of the machine, maintenance and repair work and trouble shooting in the course of operation, disposal of materials.

Observe the adjusting, maintenance and inspection duties and schedule stipulated in the operating manual, including information on the replacement of parts and equipment. This work must be executed by skilled personnel only.

Use a suitable hoisting device (crane) for the removal and instal-lation of the mould.

Use a suitable hoisting device when changing the working position of the injection unit.

Use a suitable climbing aid which complies with the safety regula-tions when suspending the injection on the crane hook.

Always inform operating personnel before beginning non-routine operations and maintenance work.

Ensure that a sufficiently wide area is cordoned off around the maintenance work being carried out.

When the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent restart-up: secure the main switch with a lock and remove the key and/or attach a warning sign to the main switch.

When carrying out overhead assembly, maintenance or other work always use specially designed or otherwise safety-orientated climbing aids and platforms. Never use machine parts as a climbing aid. Keep the machine operating-area free of any dirt, granulate and cleaning agents.

Before carrying out any maintenance or repair work, clean the machine, in particular connection terminals and threaded connec-tions, so that they are free of oil, fuel or cleaning agents. Do not use aggressive detergents. Use lint-free cleaning cloths only.

After cleaning, examine all hydraulic hoses and pipes for leaks, loose connections, chafe-marks and damage. Rectify any faults immediately.

Always tighten any screwed connections that have been loosened during maintenance and repair to the required torque.

If safety devices need to be removed for set-up, maintenance or repair purposes, they must be refitted and checked immediately upon completion of the maintenance and repair work.

Ensure that all replaced parts and materials are disposed of safely and with the minimum of environmental impact. Observe the instructions of the material manufacturer.

On the electric machine ALLDRIVE the locking switch on the safety door can be mechanically deactivated (see chapter 8.6 in the ALLDRIVE operating manual).

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Warnings of particular sources of danger - electrical energy

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical supply system.

When inspection, maintenance, and repair work is being carried out on the control cabinet or other live parts, the machine parts must be de-energized, if specified. Before starting any work check these parts for the presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements.

The electrical equipment of the machine is to be inspected and checked regularly. Defects such as loose connections or scorched wires must be replaced immediately.

In the vicinity of the control cabinets for frequency converters (on machines with electric drives), electro-magnetic fields can be generated in a range of up to approx. 30 cm from the control cabinet surface. These electro-magnetic fields may slightly exceed the limit values specified in the DIN VDE 0848 (1995-07) regulations for exposure range 2 and may be hazardous for persons carrying implanted electronic health-supportive equipment.

Gas, dust, steam and smoke Before carrying out welding, flame cutting and grinding work, clean the machine and its surroundings so that it is free of dust, granulate, oil and other flammable materials. Cover the hoses and provide adequate ventilation (risk of fire or explosion).

When processing different types of plastic materials, gases can be emitted that may be aggressive and/or detrimental to health. Ensure that adequate ventilation and exhaustion is provided. Do not simply let gases escape into the atmosphere. They must be collected and neutralised.

Suitable fire-extinguishing facilities, in particular for the types of materials being processed on the machine, as well as personal protective equipment to protect against possible gas formation, must be made readily available.

Hydraulic and pneumatic equipment

Work on hydraulic equipment must only be carried out by persons with specialized knowledge and experience of hydraulic systems.

Check all cables, pipes, hoses and screwed connections regularly for leaks and visible damage. Repair any damage immediately.

Depressurize all system sections and pressure pipes (pressure accumulator, hydraulics, compressed air) in accordance with the specific instructions for these assembly groups, before carrying out any repair work involving them.

Adhere to the inspection and maintenance schedules of the hydraulic bladder-type accumulator. Observe the separate instruc-tions of the manufacturer.

Hydraulic and pneumatic hoses must be laid and fitted correctly. Do not interchange the connections. The fittings, lengths and quality of the hoses must comply with the technical specifications.

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SAFETY INSTRUCTIONS

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Oil, grease, plastics and other chemical substances

Observe the product-related safety regulations when handling oil, grease, plastic and other chemical substances.

Extreme care must be taken when handling hot operating materials and processing aids, in particular hot plastic materials (danger of burning or scalding)!

Transport of the machine Use only appropriate lifting gear and load-bearing equipment of adequate capacity during transport and loading operations.

Appoint a person with the relevant specialized knowledge to assist in lifting operations.

Lift machines properly with lifting gear in accordance with the instructions in the operating manual (observe fixing points for lifting gear etc.)

Use only suitable means of transport of adequate load capacity.

Fasten the load safely using suitable fixing points.

Before loading, apply devices provided for securing machine and injection unit against unintentional position change. Attach appro-priate warning signs.

Carefully refit and fasten all parts which have been removed for transport purposes before re-commissioning the machine.

Cut off the external power supply even if only minor changes in location are carried out. Reconnect the machine to the mains supply properly before recommissioning.

When recommissioning, proceed only in accordance with the operating instructions.

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Personal protective equipment..\

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As a protection against possible dangers during conversion, mainte-nance or repair work the machine operator must wear personal protective equipment. If required by the production procedure this protective equipment must also be worn during machine operation.

The following personal protective equipment is stipulated:

I M P O R T A N T

Before deciding on the choice and application of personal protective equipment, the operating authority of the injection moulding machines has to carry out an inidiviual assessment of the degree of risk involved, in accordance with the law of safety precautions at the place of work, which takes into consideration in particular the type and extent as well as duration and probability of the risk involved for the operating personnel.

This assessment is to be directive in the choice of suitable personal protective equipment.

The personal protective equipment must be inspected regularly and kept in correct working order.

Heat-resistant protective gloves, acc. to DIN EN 420/EN 407For all work with hot objects such as the plasticizing cylinder, screw and nozzle.

Eye protection / face mask according to DIN EN 166For all work on the heated plasticizing unit and work that presents a risk for eyes and face.

Safety shoes, category S2 according to DIN EN 345For work where there is a risk of injury to the feet due to falling objects.

Particle-filtering face mask, category FFP3, acc. to DIN EN 149For all work where there is a possibility of air impurities.

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Transport and operating conditions..\

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Transport conditions During transport of the machine the following environmental-specific values for temperature and humidity must be fulfilled (EN 60204-1 : 1997 pt. 4):

permissible temperature range:-25 C to 55 C-13 F to 130 F

permissible relative air humidity:min. 20 %max. 80 %

Operating conditions During operation of the machine the following environmental-specific values must be fulfilled (EN 60204-1 : 1997 pt. 4):

voltage supply0.9 ... 1.1 of the nominal voltage

frequency0.99 ... 1.01 of the nominal frequency, when permanently on0.98 ... 1.02 when briefly on

electro-magnetic compatibility (EMC)in accordance with EEC guideline (EMC 89/336)

permissible temperature range:5 C to 40 C40 F to 105 F

minimum hydraulic oil temperature:15C, 60 F

permissible relative air humidity:max. 50 % at a max. temperature of 40C (104F)

the temperature of the cooling water supply must be above the temperature at which condensation takes place. Condensation could otherwise damage machine components.

maximum installation height:max. 2000 m above sea levelmax. 6600 ft above sea level

Ambient light intensity, in particular around the clamping unit:min. 500 Luxfollowing EN1837/1999; in accordance with German operational safety standard (BetrSichV), App. II, section 2.4

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Introduction..\

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1 Introduction

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Introduction

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Technical data ALLROUNDER 570 C

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1.1 Getting to know your ALLROUNDER

1.1.1 Technical data ALLROUNDER 570 C

Technical data 570 C - EuropeMachine model 570 CEUROMAP size 1) 2000-800Clamping unitClamping force max. kN 2000Closing force max. kN 70Opening force / increased max. kN 50 / 520Opening stroke max. mm 650Mould height min. mm 300Daylight between platens max. mm 950Tie-bar clearance mm 570 x 570Mould platen size (hor x vert) mm 795 x 795Weight of mov. mould half max. kg 1500Ejector force max. kN 66Ejector stroke max. mm 225Hydraulics, drive, generalDrive power of hydraulic pump kW 22Total connected load 2) kW 38.3Colour: plastic coated, structure light grey / mint green / canary yellowControl cabinetSafety standard DIN EN 60204Socket combination (1 single phase, 1 three-phase) 1 x 16 AInjection unit 800Screw diameter mm 45 / 50 / 55Effective screw length L/D 22 / 20 / 18Screw stroke max. mm 200Calculated injection volume max. cm 318 / 392 / 474Shot capacity max. g/PS 291 / 359 / 434

Material throughput 4) max. kg/h PS 46 / 53 / 59max. kg/h PA 6.6 23 / 27 / 30

Injection pressure3) max. bar 2470 / 2000 / 1650Injection flow 3) max. cm/s 174 / 214 / 260Back pressure positive/negative max. bar 350 / 190Circumferential screw speed max. m/min. 56 / 62 / 69Screw torque max. Nm 880Nozzle contact force max. kN 70Nozzle retraction stroke max. mm 400Installed cylinder heating power kW 13.2 / 6Installed nozzle heating power kW 0.6Material hopper capacity l 50Machine dimensions and weights of basic machineOil capacity l 290Net weight ca. kg 7450Electrical connection (pre-fused) 2) A 100

1 1st figure: clamping force (kN) 2nd figure: max. dosage volume (cm3 ) x max. injection pressure (kbar)2) Values apply to 400 V/50 Hz. The load is symmetrically distributed over the 3 phases (observe when adding machine equipment).3) A combination of max. injection pressure and max. injection flow (max. injection capacity) can be mutually exclusive.4) Deviations are possible, depending on process settings and type of material used.

The technical data correspond to the current level when going to print. We reserve the right to modify specifications in the interest of further development..

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Technical data ALLROUNDER 570 C

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Technical data 570 C - USA

Machine model570 C 220 tons 15.3 oz

Clamping unitClamping force max. US tons 220Closing force max. US tons 7.7Opening force / increased max. US tons 5.5 / 57.2Opening stroke max. inch 25.59Mold height min. inch 11.81Daylight between platens max. inch 37.4Tie-bar clearance inch 22.44 x 22.44Mold platen size (hor x vert) inch 31.3 x 31.3Weight of mov. mold half max. lbs 3300Ejector force max. US tons 7.26Ejector stroke max. inch 8.86Hydraulics, drive, generalDrive power of hydraulic pump kW 22Dry cycle time for opening stroke 5) s-inch 2.6 - 15.71Total connected load 1)2) kW 38.3Colour: plastic coated, structure light grey / mint green / canary yellowControl cabinetSafety standard ANSIInjection unit 15.3 ozScrew diameter inch

mm1.77 / 1.97 / 2.17 45 / 50 / 55

Effective screw length L/D 22 / 20 / 18Screw stroke max. inch 7.87Calculated injection volume max. inch 19.4 / 23.9 / 28.9Shot weight max oz PS 10.3 / 12.7 / 15.3Material throughput 4) max. lbs/h PS

max lbs/z PA 6.6101.2 / 116.6 / 129.850.6/ 59.4 / 66

Injection pressure 3) max psi 35800 / 29000 / 23900Injection flow 3) max in/s 10.6 / 13. 1 / 15.9Back pressure positive/negative max. psi 5080 / 2760Circumferential screw speed max. ft./min. 184 / 203 / 226Screw torque max. ft lbs 650 Nozzle contact force max. US-tons 7.7Nozzle retraction stroke max. inch 15.75Installed cylinder heating power kW 13.2/ 6Installed nozzle heating power kW 0.6Material hopper capacity lbs 80Machine dimensions and weights of basic machineOil capacity US-gall. 76.62Net weight (without oil) lbs. 16390Electrical connection (pre-fused) 1) A 125Electrical connection (pre-fused) Motor 2) A 50 Heat A 40

1) Values apply to 230 V/60 cycles. The load is evenly distributed over three phases.2) Values apply to 460 V/60 cycles for motor and control resp. 230 V/60 cycles for heating. The load is evenl distributed over three phases (depending on

optional equipment ordered).3) A combination of max. injection pressure and max. injection flow (max. injection capacity) can be mutually exclusive, depending on the equipment-

related motor output. 4) Deviations are possible depending on process settings and material type.

The technical data correspond to the current level when going to print. We reserve the right to modify specifications in the interest of further development.

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Dimensions for mould installation / ejector connections

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1.1.2 Dimensions for mould installation / ejector connections

Mould dimensions 570 CPart 1 - Europe

The technical data specifications refer to those at the time of going to print. We reserve the right of modification in the interest of continuous further development.

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Mould dimensions 570 CPart 2 - Europe


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Moud dimensions 570 CPart 1 - USA


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Mold dimensions 570 C Part 2 - USA


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Ejector coupling The two following illustrations each show a different method for the connection of an ejector:

With compulsory ejector retraction.The bolts of the hydraulic ejector and the mould are connected firmly together.

1 coupling element2 fixed connection3 mould ejector bolt

With thrust pad.There is no fixed connection between the hydraulic ejector bolt and the mould. The ejector bolts are only hydraulically actuated during advancement. Springs in the mould push them back into place.

1 coupling element2 no connection3 mould ejector bolt

Ejector length 570 C = max. 358 mm / 14.1

I M P O R T A N T

Select the ejector length to be at least 1-2 mm shorter than the maximum dimension, so that the ejector system is not under pressure when the mould is closed.

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Dimensions of the coupling element

570 C = Part no. 95518.

1 mould2 mould ejector bolt3 connection piece4 adjustment screw5 lock nut6 coupling piece

Compulsory retraction Blunt ejection

Coupling with connection element as an adjustable ejector bolt

Coupling with adjustment screw as an adjustable thrust pad

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Mould weights

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1.1.3 Mould weights

Maximum permitted mould weights (mould mass)

The maximum allowed mould weights for the moving mould half can be viewed in the following table.

Do not exceed these values for any reason. This could lead to production problems and premature wear.

Maximum mould weights

Machine model

Maximum weight of moving mould

half

kg / lbs

Maximum weight of moving mould half

on index unit(multi-comp. machine)

kg / lbs

Max. weight of moving mould half on rotary

table(kg)

Maximum weight of mould

(kg)

320 A 320 / 705 300 / 661 480 / 1058

370 A 360 / 793 360 / 793 540 / 1190

420 A 600 / 1323 450 / 992 900 / 1984

470 A 760 / 1675 450 / 992 1140 / 2513

520 A 1500 1000 / 2205 750 / 1653 1500 / 3307

520 A 1100 / 2425 750 / 1653 1600 / 3527

570 A 1300 / 2866 750 / 1653 2000 / 4409

270/320 C 180/270 / 397/595 1)

1 With optional support of moving mould mounting platen

400 / 882

370/420 C 600 / 1323 400 / 882 900 / 1984

420 C 1300 650 / 1433 400 / 882 1000 / 2205

470 C 1500 800 / 1764 600 / 1323 1200 / 2646

520 C 1500 1000 / 2205 1500 / 3307

470/520 C 1250 / 2756 750 / 1653 1800 / 3968

570 C 1500 / 3307 750 / 1653 2200 / 4850

221 K 75 / 165 150 / 331

170 S 36/55 / 79/1211) 85 / 187

270 S 135/200 / 297/4411) 300 / 661

370 S 360 / 793 360 / 793 540 / 1190

470 S 760 / 1675 600 / 1323 1140 / 2513

520 S 1050 / 2315 600 / 1323 1600 / 3527

570 S 1400 / 3086 750 / 1653 2100 / 4630

630 S 2500 / 5511 1000 / 2205 3800 / 8377

720 S 3600 / 7936 2000 / 4410 5300 / 11684

820 S 5000 / 11023 2000 / 4410 7500 / 16535

920 S Golden Edition 6000 / 13228 9000 / 19841

920 S 8000 / 17637 12000 / 26455

1200 T 400 / 882 750 / 1653

175 V 18 / 40 2)

2 upper mould half

60 / 132 55 / 121

275 V 65 / 143 2) 120 / 264 200 / 441

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Support of the moving mould platen

Without support

Support of the moving mould platen

(Support for the vertically acting forces e.g. mould weight)

Mould carrier ( 0

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Machine transport

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1.1.4 Machine transport

Transporting the machine A crane is required to transport the machine. The machine weight without oil is as follows:

The machine weight can be significantly higher depending on the machine equipment.

The machines centre of gravity is located in the machine base near the fixed mounting platen. The centre of gravity is indicated on the operating side of the machine base. The position of the centre of gravity can vary depending on the machine equipment.

Transport jig570 C

Fr den Transport sollte auf jeden Fall die im Maschinenwerkzeug enthaltene Transportvorrichtung verwendet werden.

Transport jig 570 C:Transport jig metric: Part no. 242702,Transport jig USA: Part no. 244844,Transport jig Japan: Part no. 244702.

Transport with a crane570 C

Attach the support brackets (4) of the transport jig to the fixed mould platen (see illustration).

Tighten the head screws (2) to a torque of 710 Nm (523.6 ft lbs).

Place the transport belts through the support brackets as shown in the illustration.

Loop one end of the transport belt (1) around the upper tie-bar of the clamping unit.

Place the other end of the belt through the loop and pull it to a knot.

Guide each free end of the two transport belts through the support brackets (see illustration) and suspend the end onto the crane hook.

Attach the 2 head screws (3) with nuts to both support brackets directly in front of and behind the transport belt.

Unscrew the nuts or screws on the machine feet and remove the transport pallets.

If it is not possible to transport the machine to the site of instal-lation with a crane, we recommend the use of a heavy-duty roller system with hoist.

Machine model Machine weight570 C 2000-800 7750 kg / 17,086 lbs

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S A F E T YI N S T R U C T I O N S For transport purposes, the movable platen of the machine must

be opened to the maximum stroke.

When transporting the machine without delivery pallet, and when applying hoisting equipment, the welts provided for this purpose in the floor of the machine base must be used to avoid slipping.

Use the transport belts supplied when suspending the machine on a crane.

1 Transport belts2 Head screws3 Head screws with nuts4 Support bracket

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Machine installation

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1.1.5 Machine installation

Explanation The machine requires neither foundation nor bracing. Remember to leave enough free space for conversion and maintenance work, see floor plan.

To install the machine, proceed as follows for best results:

Transport the machine to the place of installation, but do not set it down yet.

Place the machine feet (3) with the centring bores exactly under the set screws (1).

Lower the machine slowly to the floor.

Adjust the set screws (1) so that the machine stands horizontal.

Place an industrial spirit level in longitidunal and transverse direc-tions on the lower tie-bars of the clamping unit.

x: max. 10 mm!

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Check the alignment in longitidunal and transverse directions in two positions.

The machine must be aligned so that the error in both directions does not exceed 0.1 mm/m (as far as possible).

Check the setting again after several hours of operation.

Secure the set screws with the lock nuts provided.

Tighten first the upper and then the lower lock nuts (2). There is only one lock nut (top) on the middle machine feet.

I M P O R T A N T

If your machine is equipped with a hydraulic pressure accumulator, please refer to chapter 15.4 also.

For transport by air or sea the pressure accumulator is discharged and must be re-charged with nitrogen before setting into operation.

If your ALLROUNDER is equipped with a swivel crane and electro hoist chain, the installation instructions in chapter 13.4 must be observed.

Pressure accumulator and swivel crane are not available for the ALLROUNDER C GOLDEN EDITION.

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Transport protection on the monitor housing

The monitor housing is firmly screwed onto the machine with clamping elements (1) for transport purposes, so that the monitor housing can not move.

Unscrew the head screws (2) at the top and bottom by approx. revolution.

The monitor housing must now swivel easily.

I M P O R T A N T

Tighten the head screws for clamping the transport device of the monitor housing before transporting the machine again.

If your ALLROUNDER is equipped with a swivel crane and electrical hoist chain, the installation instructions in chapter 13.4 must be observed!

Pressure accumulator and swivel crane are not available for the ALLROUNDER C GOLDEN EDITION.

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Floor plan ALLROUNDER 570 C - Europe

S A F E T Y I N S T R U C T I O N S Clearance zone according to EN349 (at least 500 mm / 20) must

be observed. Otherwise there is a risk of the operator being squashed between the machine and other objects by moving aggregates!

( GT1

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Floor plan ALLROUNDER 570 C - USA

S A F E T Y I N S T R U C T I O N S Clearance zone according to EN349 (at least 500 mm / 20) must

be observed. Otherwise there is a risk of the operator being squashed between the machine and other objects by moving aggregates!

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Cooling water and pneumatic connections

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1.1.6 Cooling water and pneumatic connections

Water quality Your injection moulding machine is equipped with high-quality aggre-gates and components which become hot during operation and must therefore be cooled.

In order to ensure a problem-free operation, the quality of the water must fulfil the following requirements:

The cooling water must be free from contaminations such as floating or sinking particles or algae.

Using cooling water which does not fulfil the above criteria, can lead to malfunctions and damage (e.g. corrosion, lime formation). In this case we cannot accept any obligation of warranty.

If in doubt, have your water analysed or consult a firm specialised in circulating cooling systems.

I M P O R T A N T

Inspect the flow volume and return temperatures of your cooling water at regular intervals. Significant changes usually point to a narrowing of the cross-section of the cooling circuits. We recommend decalcifying the cooling circuits from time to time. Use a commercially available decalcifier for this purpose.

Cooling water additives such as anti-frost, anti-alga, decalcifiers etc. must not contain substances which react with the plastic fittings or with copper and aluminium elements. Appropriate cautionary measures to protect the environment are also to be taken.

Hydrological data max. unitOverall hardness < 15 dHCarbonate hardness when using hardness stabi-lisers

< 5.6 dH

pH-value 6.5-8.5 LCE 1

1 LCE = lime-carbon equilibrium

Conductivity < 50 mS/mChloride Cl < 100 mg/lGrain size < 0.1 mm

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Compressed air connection If your machine is equipped with a pneumatic system, the machine must be connected to the compressed air network. The connection is made through the pneumatic maintenance unit which is to be found on the machine base (see illustration).

The compressed air which is fed to the maintenance unit must be free of oil and contaminations. Any condensation is collected in the water separator on the maintenance unit. The condensation must be discharged via the outlet cock before the maximum level is reached.

The highest pressure level from the compressed air network must not exceed 10 bar.

1 Connection for compressed air2 Pressure adjustment valve

Connect a compressed air supply line DN 9 to the pneumatic maintenance unit.

Connect the supply line to the connection pieces (1) and tighten it with a hose clip.

Check that the output pressure complies with the value stipulated on the designation label near the maintenance unit and adjust it if necessary, proceeding as described in chapter 9.8.9.

I M P O R T A N T

The pneumatic system must only be operated via the pneumatic maintenance unit.

Compressed air which has not ben processed by the maintenance unit can cause malfunctions or a total failure of the pneumatic components.

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Cooling water connection Supply and return connections for the machine cooling system are located on the rear side of the machine on the fluid distributors (see illustration).1

For the cooling water supply line (inlet) you must use a filter.

1 cooling water supply DN 252 cooling water return DN 25

I M P O R T A N T

Do not use pipes for connection, use hoses only. Remove connection nipples which are not required from the cooling water manifold.

This interrupts the flow. If a value is available in the data set for this cooling circuit, water may jet out if the nipple remains inserted.

1 depending on the machine equipment

Connection dimensions

HoseSupply pressure

staticbar / psi

Supply pressure dynamicbar / psi

Supply temperature

C / FSupply: DN 25 max. 8 / 120 min. 4 / 60 max. 25 / 77Return: DN 25 max. 80 / 176

Pressure difference between supply and return min. 4 bar / 60 psi.

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Connection assignment of an optional cooling water manifold

1 power supply (on rear side)2 insert thermocouple connector here (observe x-designation)3 knob for manual adjustment4 feed zone5 oil temperature6 control cabinet7 supply8 shut-off valve9 return10 water processor

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Connection assignment of an optional cooling water manifold

1 Connection for power supply 5 V (on rear side)2 insert thermocouple connector here (observe x-designation)3 feed zone4 oil temperature5 control cabinet6 supply7 switch-off valve8 return9 water processor

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Cover of the cooling water manifold

In order to connect the thermocouples 1 to the respective sockets on the cooling water manifold, the cover of the cooling water manifold must be swivelled open.

1 cover2 screw3 screw (do not unscrew)

To open the cover Unscrew the two upper screws (2) at the front and the back of the cover (the screws (3) must not be unscrewed).

Swivel the cover to the front.

Connect the thermocouples.

To close the cover Swivel the cover back again.

Attach the fixing screws (2) and tighten them.

S A F E T YI N S T R U C T I O N S Never operate the machine when the cover is open or not correctly

fastened.

1 not standard

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1.1.7 Electrical connections

S A F E T Y I N S T R U C T I O N S The electrical connections of the machine must be carried out by a

suitably qualified specialist in accordance with VDE (for USA, Canada: NFPA 79) as well as any other regulations applicable to your country. All safety regulations must be strictly observed.

Connection values A serial label with technical data is located on the control cabinet of the machine.

I M P O R T A N T

Your supply voltage must correspond to the working voltage indicated on the machine ratings label or mains connection label on the machine.

The connection values for USA and Canada are described at the end of this chapter.

Faulty-current circuit breaker If your machine is equipped with a frequency converter and is protected by a faulty-current circuit breaker, a universal-current type faulty-current circuit breaker with the following features must be used:

Type B in accordance with IEC 60755 A2,

Universal-current type (in acc. with EN 50178 chapter 5.2.11.2),

Pick-up current => 300 mA (no operator safety),

Reaction time => 300 ms.

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Motor The machine is driven by a three-phase motor which was connected to the control cabinet before leaving the factory.

Power connection cable(s) The machine may have one or two connection cables, depending on the size and equipment of the machine. Two cables are required if the machine is to be operated with the type of connection "Separate power for heating and motor". Otherwise 2 cables are also needed when the total amount of power needed is so great that it cannot be connected together with the bridges.

Which type of connection is stipulated for your machine is to be taken from the information label on the inside of the control cabinet door (see illustration).

The values for the back-up fuse are entered in the boxes "a", "c" and "e".

The stipulated voltage is entered in the boxes "b", "d", "f", as on the serial label.

The connections must only be carried out in accordance with this information.

Example:Box a = 63 A Back-up fuse for total nom. powerBox c = 16 A Back-up fuse for heatingBox e = 50 A Back-up fuse for motor

With this specification the power for the heating and motor can either be connected together or separately.

If however only boxes "c" and "e" are marked, the power for the heating and the motor must be connected separately.

The connectable conductor cross sections must be determined in accordance with the cable length and fusing.

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Removing the cover To connect the mains cable, the cover of the control cabinet must be removed.

Proceed as follows:

First you must ascertain which variation of fixture is applicable to your machine:

Cover with 4 outer screws on top

Cover with oblique front edge, and 2 inner screws

Cover with straight front edge, and 2 inner screws

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Removing the cover

Cover with outer 4 screws on top

Removing the screws Unscrew the 4 screws located on the top of the cover and remove them.

Lifting off the cover Lift off the cover.

Place the mains cable through the opening provided in the control cabinet.

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Cover with oblique front edge, and 2 inner screws

Removing the screws Open the doors of the control cabinet.

Look for the two screws. (They are each located 20 cm away from the outer wall).

Unscrew the two screws and remove them.

Pushing back the cover Push the cover back approx. 5 mm.


Insert the mains cable through the opening provided in the control cabinet.

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Cover with straight front edge, and 2 inner screws

Removing the screws Open the doors of the control cabinet

Look for the two screws. (They are each located 20 cm away from the outer wall).

Unscrew the two screws and remove them.

Lifting off the cover Lift the front edge of the cover slightly.

Pulling the cover to the front Pull the cover approx. 1 cm to the front.


Place the mains cable in the opening provided in the control cabinet.

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Power connection Guide the mains cable through the opening provided in the high current control cabinet.

Connect the yellow/green protective earth cable to the yellow/green earthing terminal and connect N to the N-terminal.

Connect the L1, L2, L3 conductors to the L1, L2 and L3 terminals, see illustration.

Tighten the terminals.

Check whether all screw terminals are well tightened. They may have become loose during transport.

Mains connection with separate heating current

Connect the green/yellow protective earth cable to the PE-terminal and N1 to the N1 terminal.

Remove the bridge between terminals L1 and L4, L2 and L5, L3 and L6, N and N1.

Connect the heating current cable to L4, L5 and L6.

Tighten the terminals.

Mounting the cover Mount the cover onto the control cabinet.

Proceed in reverse order, as described for demounting.

Mains connection terminals

1 PE terminal 2 N1terminal 3 L4, L5, L6 terminal 4 L1, L2, L3 terminal 5 N terminal 6 Main switch

If the machine requires high connection values it will be equipped with an additional high-current cabinet. The mains connection for this version is shown in the following illustration:

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Mains connectionfor additional cabinet

(depending on the machine equipment)

1 PE terminal2 N terminal3 L1, L2, L3 terminal4 N1 terminal5 L4, L5, L6 terminal6 main switch

S A F E T Y I N S T R U C T I O N S The machine must only be connected to the mains by a

qualified specialist.

Tighten all screw terminals in the control cabinet. If the terminals are not tightened the main switch and other compo-nents may suffer irreparable damage.

When working on the electric or hydraulic system, always switch off the main switch and lock it to prevent it being inadvertently switched on again.

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Inspecting / adapting low voltage

In order to guarantee a disturbance-free function of the controller and the control elements, the low voltage of the machine must be 24 V (26-28 V in unloaded condition). The low voltage is dependent on which mains voltage the machine is connected to.

The low voltage can be changed by varying the connection to the taps on the terminal strip (1) connected to the transformer (see illustration).

Please ensure that the cables L1, L2 and L3 and the bridges (2) are connected in accordance with the available mains voltage in your area by referring to the table on the transformer or in the circuit diagrams.

Reconnection must only be carried out by a suitably qualified electrician under observance of the safety regulations.

I M P O R T A N T

Refer to the group 2 circuit diagram (low voltage supply).

The circuit diagrams are supplied in the machine control cabinet.

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Power connectionsfor USA, Canada

The following information applies only to machines in the USA and Canada.

Motor The machine is driven by a three-phase A.C. motor which is connected to the control cabinet before leaving the factory.

Supply cables for the power connection

The machine is connected to the mains via one or two power supply cables, depending on the equipment installed. Two supply lines are required if the machine is to be operated with separate heating and motor current. Two supply lines will also be necessary if the total rating of the machine is so high that it cannot be connected together with the bridges. Which connection type is specified for your machine can be taken from the label on the inside of the control cabinet door (see illus-tration).

The pre-fusing values are entered at a, c and e.

The voltage specified on the machine rating plate is entered at b, d and f.

The power rating of the motor (in kW and hp) is entered at g and i. The stated power rating applies to the drive of the hydraulic pump, any connected electrically driven auxiliary axes are not included.

The fields h and j contain the values for the

- full-load current in accordance with CSA 22.2 no. 14, table 18 and

- locked - rotor current in accordance with CSA 22.2 no. 14, pos. 5.7 (the locked rotor current is six times the current indicated in table 18).

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The temperature values given in C and F are the max. tempera-tures permissible for the connection line.

The values entered at Class J / AJT* are provided to help select the correct mains fuse.* (Fuse type by Ferraz Shawmut Inc, Newburyport, MA 01950 USA. Other fuse types may be used if they have the same characteristic values.).

The connections must have this form of identification.

Example:Field a = 63 A Pre-fusing of total nominal currentField c = 16 A Pre-fusing of heatingField e = 50 A Pre-fusing of motor

These specifications mean that the power for the heating and for the motor can be connected either together or separately.

If however only the fields c and e are marked, the current for the heating and motor must be connected separately.

The connectable conductor cross sections must be determined in accordance with the cable length and fusing.

Now proceed with the power connections, as described in the previous pages of this chapter.

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1.1.8 Filling the hydraulic oil

Oil quantities You need hydraulic oil in accordance with DIN 51524 part 2 HLP46, DIN 51519 (see chapter 9.9 for selection of permissible oil types).

Alternative hydraulic fluids must not be used without our explicit written consent - otherwise no guarantee!

Please take the required oil quantities from the following table:

Calling up the oil level display The machine must have been previously connected as described in chapter 1.1.7.

Put main switch to I (red/yellow switch on control cabinet).

When the request to press controller start key is displayed, press the controller start button under the screen of the monitor.

The alarm message Alarm S925 oil level Oil level below min. is displayed on the monitor.

The pump motor cannot be switched on.

1 Controller start key2 Emergency stop button3 Reading device for transponder cards (user access rights)4 Reading device for CompactFlash (memory medium)5 USB interface for PC keyboard

Machine Oil quantity270 C 165 litres / 43.6 US gall.320 C 165 litres / 43.6 gall. 420 C 235 litres / 62 US gall.470 C 235 litres / 62 US gall.570 C 290 litres / 84.5 US gall.

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Panel selection Call up the main group Production control with this key.

Call up the superior group Valves/switches with this key.

Call up the parameter panel Valves/switches control circuit with this function key.

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Filling in the oil Unscrew the oil tank lid with air filter at the front of the machine base (to the left).

Pour in the oil. Observe the handling and storing recommendations of the fluid manufacturer. Use a special filter unit for hydraulic fluid systems when filling the tank. Contaminations in the oil can lead to malfunctions! A suitable filter unit can be ordered from ARBURG (Part no. 529475, spare filter PN 529476).

While filling in the oil, watch the positions S923, S924 and S925 in the parameter panel Valves/switches control circuits. You will find an explanation of the valve and switch displays in chapter 8.1.

Switch display on machine without oil filling:

S923 = marked,

S924 = not marked,

S925 = not marked.

Keep filling with oil until S925 is marked.

Now fill more slowly until S924 is also marked.

Pour in another 10 litres approx.

S923 must remain marked!

If you pour in too much oil, the marking at S923 is erased. The motor can not be switched on.

Switch display with oil filled to correct level:

S923 = marked,

S924 = marked,

S925 = marked.

no or too little oil correct oil level overfilled

Motor can not be switched on

Motor can not be switched on

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Replace oil tank cover with air filter and turn to right to close.

1 open2 close

I M P O R T A N T

Before setting into operation, the direction of rotation of the motor must be checked (see chapter 1.1.9).

Input low speeds and pressure values for the first axis movements. This allows any air that is trapped in the hydraulic system to escape gently.

Then load the start programme from the Compact-Flash system and vent the whole hydraulic system as described in chapter 9.8.4.

It can be necessary to top up the oil level after a few axis movements have been carried out.

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1.1.9 Checking the direction of rotation of the pump motor

Switching on the motor You cannot switch on the motor if there is no oil in the tank!

The tank is already filled with hydraulic oil (acc. to 1.1.8). The direction of motor rotation must now be checked.

To do that turn on the machine (read section 1.4.1 Switches and their functions beforehand).

Turn the main switch to I (red/yellow switch on front door of control cabinet).

When the prompt press start key appears on the monitor, press the start key underneath the monitor, see illustration.

Switch on the motor very briefly and immediately off again with the motor on/off keys on the manual control panel (see illustration).

Observe the direction of motor rotation when the motor is activated (a second person can do this).

Does it rotate in the direction indicated by the arrow on the motor housing?

YESYour machine is now ready for the test run. You may skip the following points.

NO You cannot operate the machine in this manner. Please go on to the next point.

Switch the machine off.

Cut off the power supply (pull power plug).

Interchange two of three wires L1, L2, L3 on the power cable on the terminal strip inside the control cabinet (see 1.1.7 Electrical Connections).

Inspect the direction of motor rotation again (as outlined above).

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