Manual de Operacion Maquinas ENGEL

duo
Service Manual - Machine

DUO 16050/1500
Serial No.:175612
WARNING!
Improper use of the machine can lead to severe injury to persons and
damage to equipment!
Before operating the plant or performing any maintenance, you must
read this instruction manual carefully, and familiarize yourself with the
safety equipment.
Do not use the plant without appropriate training.
Manufacturer: ENGEL AUSTRIA GmbH

A-4311 Schwertberg
Tel.: +43.50.620.0
Fax: +43.50.620.3609
e-mail: service@engel.at www.engelglobal.com
Person responsible for Mörwald Johann

documentation
Version: G/11/30/6/21
Printing date: 21.2.2011
Language Englisch
Translation of original instruction manual
The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed, trans-
mitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (§12 and §13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
© Copyright by ENGEL Austria Ges.m.b.H.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 PROPER USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 NORTH AMERICAN APPLIED STANDARDS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 APPLICABLE EUROPEAN STANDARDS AND REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 TEXT FORMATTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 SCREEN LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 SWITCHING UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 MACHINE OVERVIEW DUO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 PICTOGRAPHS FOR NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 PICTOGRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 SURVEY SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 SAFETY EQUIPMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 EMERGENCY STOP BUTTONS FOR PLANT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 FUNCTIONING OF THE SAFETY GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 CLOSING AREA ACKNOWLEDGEMENT (AS OF DUO 800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 AUTOMATIC SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 SAFETY GUARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6 STEP SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.7 MECHANICAL CLOSING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 ADDITIONAL EQUIPEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 MOUNTING AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 BEHAVIOR IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 RESCUE ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 SAFETY CONFORMITY PURSUANT TO MACHINE DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1 NOT SAFETY-COMPLIANT MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 SAFETY-COMPLIANT MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION AND COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1 AMBIENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1 FOUNDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 CONNECTION OF INJECTION FRAME AND CLOSING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 REMOVE THE TRANSPORTATION SAFEGUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1 REMOVE THE CLAMPING UNIT TRANSPORT SAFETY BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 LEVELING THE INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 ALIGNMENT OF THE STATIONARY AND MOVING MOLD FIXING PLATEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 FLOOR ANCHORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3 VENTILATION PRESSURE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.4 CLEANING AFTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6 SAFETY GUARDING ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7 CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.1 ELECTRIC CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.2 COOLING WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.3 COOLING WATER CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.4 COOLING WATER CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.5 THROUGHPUT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 COMPRESSED AIR CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1 STARTING THE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2 CONNECTING THE INJECTION UNIT TO THE STATIONARY MOLD FIXING PLATEN . . . . . . . . . . . . . . . . . . . . . . . 72
SETTING UP FOR INJECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1 NOZZLE CENTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 CORRECT CRANE LIFTING OF MOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1.1 ATTACH BOTH MOLD HALVES AT THE SAME TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.1.2 ATTACH EACH MOLD HALF INDIVIDUALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.2 CORRECT CENTERING OF MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2.1 STANDARD APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2.2 HEAVY MOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2.3 SPECIAL APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2.4 MOLD ANTI-TWIST SAFEGUARD (ROTATIONAL CENTERING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 CORRECT MOUNTING OF MOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3.1 MOUNTING BOTH MOLD HALVES AT THE SAME TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3.2 INDIVIDUAL MOUNTING OF MOLD HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.3.3 FACTORS THAT CAN AFFECT THE MOLD PERFORMANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4 CHECKING THE COAXIALITY OF THE TWO MOLD HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3
2.5 INFLUENCE OF THE INJECTION MOULDING MACHINE ON MOLD CLOSING BEHAVIOR . . . . . . . . . . . . . . . . . . . 96
3 SETTING UP THE BARREL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4 CHANGING A NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5 CHANGING THE BARREL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6 CHANGING A SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7 CLEAN BARREL AND SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8 SETTING UP THE NOZZLE STROKE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9 NOZZLE STROKE LIMITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.1 CALIBRATING THE NOZZLE STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2 CHECK MACHINE - EVER-Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 CLEANING OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1 CLEANING THE CONTROL PANEL ON THE ENGEL CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.2 AIR FILTER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 MAINTENANCE OF THE SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 EMERGENCY STOP BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2 MOVING SAFETY GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.3 SAFETY GUARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.4 AUTOMATIC SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.5 MAINTENANCE SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.6 STEP SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.7 SAFETY GATE ON CLAMPING UNIT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.8 SAFEGUARDING CLOSING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.9 LOCKING OF MANUAL SAFETY GATE (FROM DUO 800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.10 LOCKING OF ELECTRIC SAFETY GATE (FROM DUO 800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.11 MECHANICAL CLOSING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.11.1 ADD-ON FOR MECHANICAL CLOSING SAFETY WITH ELECTRICAL SAFETY GATE . . . . . . . . . . . . . . . . . . . 148
4.12 SAFETY LIMIT SWITCH FOR SWIVELING OUT INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.1 LUBRICANT SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.2 CENTRAL OIL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.1.1 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.1.2 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.1.3 MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.1.4 HYDRAULIC OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.1.5 HYDRAULIC OIL FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.1.6 VENT HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.1.7 CHANGING FROM ZINC-BASED TO NON ZINC-BASED OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.2 OIL TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.2.1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.3 OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.4 AUXILIARY FLOW FILTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.5 EXTERNAL OIL FILTER STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6.6 CHECKING AND FILLING THE MEMBRANE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7 COMPRESSED AIR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8 AIR FILTER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
9 SOFTWARE UPDATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.1 PREPARING THE SOFTWARE UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.2 CARRY OUT SOFTWARE UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.3 RESTORE SOFTWARE WITH BACKUP COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9.4 FIRMWARE - UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1 DISCONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2 REMOVAL OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3 DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

1 MACHINE CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2 LIST OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.1 DESIGN DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.2 HYDRAULICS SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.3 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.4 ORDERING SPARE PARTS WITHOUT A MATERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4 Service Manual - Machine | Version G/11/30/6/21

PLANS AND PROTOCOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2 FOUNDATION PLANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3 MOLD MOUNTING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4 CERTIFICATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.1 EC DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.2 DECLARATION OF INCORPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.3 NOISE EMISSION REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5 PRESSURE ACCUMULATOR TEST CERTIFICATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
SPECIAL PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5
General
General
You have decided on an ENGEL product which is produced and supplied under strictest qua-
lity controls.
This instruction manual is an important part of the injection molding machine and intended for
any staff who work with or on the machine. Keep the instruction manual throughout the service
life of the machine, and pass it on to any subsequent owners or users. It is important to inte-
grate any amendments you receive with the instruction manual.
Structure of the system documentation:
Instruction Manual - Machine
Service manual - Machine (Commissioning, Maintenance)
Operator Manual - Machine (Operation)
Manual CD contains the following documents in PDF format: Operator,

Service and Technical Manual (Troubleshooting), schematics, data sheet,
Safety data sheets, spare parts list and optional Peripheral Unit Docu-
mentation.
Virtual Machine CC200 CD contains the installation programs for PC
simulation of the machine control unit.
Instruction Manual - Robot
Service manual - Robot (Commissioning, Maintenance)
Operator Manual - Robot (Operation)
Manual CD contains the following documents in PDF format: Opera-

tor, Service and Technical Manual (Troubleshooting), spare parts
catalog, schematics, data sheets and optional Peripheral unit docu-
mentation.
An integrated help system is available in the machine control for easier support.
This covers the Operator, Service and Technical manuals.
A plan of the electric system is located in the switch cabinet.
7
General
WARNING!
Improper use of the machine can lead to severe injury to persons and
damage to equipment!
Before operating the plant or performing any maintenance, you must
read this instruction manual carefully, and familiarize yourself with the
safety equipment.
Do not use the plant without appropriate training.
We recommend that you take part in training at one of Engel's training centers (www.engel-
global.com/training).
The main aim of this manual is to describe commissioning and maintenance of the injection
molding machine.
The manual is also designed help eliminate production failures as rapidly as possible.
Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.
Information on additional equipment is located in the chapter Additional Equipment.
Note!
The index contains a list of alarms.

General
1 Proper Use
ENGEL products are built to the current state-of-the-art, and comply with accepted safety stan-
dards.
Note that ENGEL injection molding machines must be used for manufacturing of injection
molded parts made of thermoplastics, thermosets and elastomers only, in accordance with the
instruction manual.
To this end, make sure you follow the processing instructions given by the material manufac-
turer!
(Improper processing could lead to injury or damage to equipment!)
The injection molding machines are constructed for automatic material feed.
Automatic material feed must be present at the site prior to start of production.
In case of manual material feed, a standardized mounting aid must be used.
The mounting aid can be supplied by ENGEL if required.
A mounting aid of this kind must be present at the site prior to start of production.
[See Mounting aid on page 33.]
Installation, operations, and maintenance of this machine must be performed by staff trained
for this purpose on ENGEL machines.
For damage from improper or not as agreed use, non-observation of the specifications in the
instruction manual as well as faulty operation ENGEL GmbH is not liable.
Modifying the machine invalidates its EC conformity; you are not permitted to put the machine
into operation in this case!
2 North American Applied standards and guidelines
ANSI/SPI B151.1 Plastics Machinery - Horizontal Injection Molding Machines - Safety

Requirements for Manufacturing, Care and Use
ANSI/SPI Vertical clamping unit IMM (VCIMM) - Safety requirements for manu-
B151.29 facturing, care and use
ANSI/RIA/ISO Industrial robots and robot systems - Safety requirements

10218
NFPA79 Electrical standards for industrial machinery
9
General
3 Applicable European standards and regulations
2006/42/EG Machinery Directive
2006/95/EG Low Voltage Directive
2004/108/EG EMC Directive for Electromagnetic Compatibility
EN ISO 12100-1 Machine Safety
EN ISO 12100-2 Machine Safety
EN ISO 13857 Machine Safety, Safety Distances
EN 201 Safety Information for Injection Molding Machines
EN ISO 13850 Machine Safety, EMERGENCY STOP Equipment
EN 60204-1 Machine Safety, Electrical Equipment for Machines
EN ISO 10218 Industrial Robot Safety
4 Text formatting
The following text formatting is used to provide a clear manual layout and to emphasize parti-
cularly important information:
DANGER!
Information marked with this symbol points out immediate danger which
can lead to death or serious physical injury!
WARNING!
Information marked with this symbol warns of possible danger which

can lead to death or serious physical injury!
CAUTION!
Information marked with this pictogram warns of possible danger which

can cause injury to persons and damage to equipment!

General
CAUTION!
Possible dangers which can cause damage to the machine!
Note!
Text provided with this symbol offers tips on use and other useful information.
Example:
Information provided with this symbol offers practical examples.
Numbered sequence
1. Fixes procedure way after the numbers
2. The operator must adhere absolute to the fixed operational sequence.
5 Screen layout
Depending on the machine configuration, the screen lengths can differ. Some screens support
scrolling. The screens are divided into functional areas.
Screens
CAUTION!
The parameters in the figures are purely incidental and should not be
used as a guide for machine set up.
6 Switching units
You can switch the unit display on the Setup screen.
See also:
11
General
Operator Manual im Kapitel Bedienung.
ISO
Displays units in metric system
Imperial
Displays units in imperial system
Absolute
Displays absolute values
Relative
Displays relative values (percent)
Simple conversion examples
Category ISO unit Imperial unit Conversion factors
Stroke 100 mm 3,94 in 100 mm x 0.0394 = 3.94 in
Absolute tempera- 100 °C 212 °F 100 °C x 1.8 + 32 = 212 °F

ture
Pressure 100 bar 1450.3 psi 100 bar x 14.503 = 1450.3 psi
Weight 100 g 3.53 oz.av 100 g x 0.0353 = 3.53 oz.av
Weight 100 kg 220.5 lb.av 100 kg x 2.205 = 220.5 lb.av
Force 100 kN 11.24 tf 100 kN x 0.1124 = 11.24 tf
Volume 100 cm³ 6.10 in³ 100 cm³ x 0.061 = 6.10 in³
Volume 100 l 58.1 gal/US 100 l x 0.581 = 58.1 gal/US
Torque 100 Nm 73.756 lbf ft 100 Nm x 0.7375 = 73.75 lbf ft

General
7 Machine overview DUO

Example: DUO ES 5550/800
Clamping unit side Injection unit side
1 2 3 4 5 6 7 8
13 12 11 10 9
[1] Ejector and ejector coupling
[2] Moving platen
[3] Stationary platen
[4] Barrel with nozzle
[5] Material container
[6] Injection unit
[7] Screw drive for plasticizing
[8] Hydraulic oil tank
[9] Main switch
[10] Switch cabinet
[11] Control panel with screen
[12] Operator workplace
[13] Moving safety gate clamping unit side
13
General

Safety
Safety
Injection molding machines are powerful machines that create high PRESSURES - FORCES
- TEMPERATURES that can be dangerous to persons.
To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.
Before operating a machine perform a visual check to ensure that the safety equipment is in
good working order. Also, manually check the locking systems by opening and closing all mov-
ing safety equipment.
[See Safety equipment functions on page 24.]
If you notice that safety equipment is defective,:

1. Switch off the machine immediately at the control panel and at the main switch.
2. Carry out no further activity on the equipment.
3. Immediately contact the member of staff responsible for the safety of the machine.
4. Do not resume operations until all safety equipment is working properly.
Note!
Always keep the whole plant clean. This improves its functionality and enhances operator
safety!
The floor around the plant as well as the specified access points and working places are
to be kept free of oil and pellets.
Only use marked locations as access points or workplaces.
Protect hoses against harmful influences such as acids and mechanical damage!
If you notice leakages, damage, or breaks in media lines, switch off the machine imme-
diately!
Never use plant surfaces as work surfaces. Do not use the plant as a mounting aid.
Comply with and never remove warning signs, notices or labels from machines!
Observe the safety instructions in the manual!
No access for unauthorized persons.
WARNING!
Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient pre-drying or decomposition of certain plastics can cause
the material to exit the nozzle or infeed opening in an uncontrolled way.
When working on the machine, use suitable protective clothing (safety
shoes, protective gloves, face protection, ...). Observe local safety regu-
lations for operating injection molding machines!
When working in the injection mold area, make sure the nozzle is
retracted! Make sure the barrel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufac-
15
Safety
turer!
In case of injection steps where clamping force is not fully built up,
install additional, fixed, separating safeguards in the injection molding
machine mold area, or attach directly to the mold!
WARNING!
Danger from gases hazardous to health!

Observe processing and safety instructions by the material manufac-
turer. When processing materials that can cause a health risk, always
use extraction equipment.
The user is responsible for procuring and installing the extraction equip-
ment (e.g. above the injection mold, nozzle areas, material feed open-
ing).
When using nitrogen in processes, always check the oxygen content
first before all work in the pit.
WARNING!
Danger of crushing due to moving components on the machine!

During operations never reach into, or enter, component work areas,
except at positions designed for this purpose.
Never manipulate, disable, or remove safety equipment.
Do not use any molds that protrude over the mold area of the machine.
When connecting and disconnecting media lines in case of retooling
work, make sure that the system is depressurized and switch off the
motors.
Do not work or stand below moving components, even if the plant is
switched off.
CAUTION!
Danger of damage to equipment due to improper settings!

When operating the machine, use settings that precisely match the
requirements for safe operations of the machine, molds, and peripheral
units.
ENGEL is not liable for operator errors.

Safety
WARNING!
Danger of fatal injury in case of improper maintenance!

Maintenance work and repairs to the machine must be performed by
trained and skilled staff only.
You must have comprehensive knowledge of safety precautions and
controls.
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.
WARNING!
Danger of falling and crushing in case of failure to use fixed mounting

aids!
Use suitable mounting aids for work at heights above 1.0 m (39.4 in).
Mounting aids must be provided by owner/operator if not included in
scope of order.
Unauthorized, non-permanent mounting aids can allow staff to reach
into dangerous areas of the machine.
Before you use non-permanent mounting aids, always switch off the
injection molding machine.
If you need to use a mounting aid, use equipment that complies with
local safety regulations and prevents from falling, tripping or slipping.
Never lean ladders against the machine.
Observe the additional safety instructions found throughout this man-
ual!
17
Safety
1 Pictographs for North America

Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Signs
Symbol Description
DANGER!
High speed moving parts. Do not operate with gate / guards removed or open.
Do not reach around, under, over or through gate / guards while machine is
operating. Can cause crushing injury or death.
DANGER!
High voltage. Hot surface. Turn off and lock out main power disconnect, allow
to cool before servicing. Can cause shock, severe burns or death.
DANGER!
High voltage. Before servicing turn off, lock out / tag out main power discon-
nect. Do not modify electric or hydraulic circuits unless authorized by manufac-
turer. Earth ground maschine and electrical cabinet before turning on power.
Failure to comply can cause shock, burns or death.
DANGER!
High voltage. Machine has additional disconnect(s) in other location(s). Before
servicing turn off, lock out/tag out all power disconnects. Failure to comply can
cause shock, burns or deatch.
WARNING!
High pressure molten material. Stand clear and wear protective gear when
purging and / or servicing injection system. Can cause severe burns.
WARNING!
Rotating screw. Do not operate with hopper removed or put hands or feet into
opening. Serious bodily injury can occur.
WARNING!
High pressure accumulator. Discharge all gas and hydraulic pressure before
disconnecting or disassembling tank. Can cause death or serious injury.
WARNING!
Crushing injury. If the guard over the part drop area must be modified or
removed, it is the User's responsibility to add additional guarding to prevent
reaching moving machine members when the guards are closed. Failure to fol-
low these instructions may result in serious personal injury.
WARNING!
High pressure fluid. Do not use hand to check hydraulic leaks. Relieve pressure
before loosening fittings. High pressure punctures skin. If injured, seek immedi-
ate medical help. Surgery is required to remove fluid. Can cause death or seri-
ous injury.

Safety
Signs
Symbol Description
WARNING!
High speed moving robot. Interlocked perimeter guarding must be in place and
functioning before operating robot.
Can cause serious injury.
WARNING!
Moving belt(s). Do not operate with guards removed. Can cause serious injury.
WARNING!
Arc flash and shock hazard. Refer to NFPA 70E for workplace electrical safety
and for proper Personal Protective Equipment. Failure to comply could result in
serious injury or death.
CAUTION!
Complex machine with hazards. Do not operate machine unless trained, read
and understand the Maintenance / Operator manual(s). Prior to start-up, test
safety devices per instruction manual. Do not operate machine unless inter-
locks / safety devices are in place and function properly. Do not modify machine
unless authorized by manufacturer. Failure to follow instructions could result in
injury..
CAUTION!
Only qualified persons are permitted to gain access through the keyswitch!
Remove key from keyswitch after maintenance work.
19
Safety
2 Pictographs
Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Prohibitory signs
Symbol Description and examples of labels
Admittance for authorized persons only!

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

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

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

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

Use of fork lifts or manual lifts for lifting the plant at this position is prohibited.
Do not use any credit cards, watches or small metal parts in the proximity!
Labels for magnetic holding plates in the clamping unit area
Mandatory Signs
Read documentation!
On the control panel of the machine control
Use protection equipment!

In the barrel area
Use face protection!

In the barrel and injection mold area
Use lifting point for transport!

At lifting points

Safety
Danger signs
Warning against hot surface!

In the barrel area
Warning against mains voltage!

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

In the clamping unit area
Warning against pressurized molten material!

In the barrel area
Warning against strong magnetic field!
21
Safety
Safety hints
Symbol Description
GUIDELINES FOR WORKING ON INJECTION MOLDING MACHINES:

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

Safety
3 Survey safety equipment

Example: DUO 5550/800
1 2 3 4 5 6
13 12 11 10 9 8 7
[1] Clamping unit side rear sliding safety gate

[2] EMERGENCY STOP button - red
[3] Alarm lamp (flashes in case of alarm)
[4] Nozzle sliding safety gate
[5] Injection unit side safety gate
[6] Main switch and machine type plate
[7] Rating plate on inside of control cabinet door
[8] ’’Guidelines for working on injection molding machines’’
[9] EMERGENCY STOP button - red
[10] Locking safety gate
[11] Step safety
[12] Clamping unit side front sliding safety gate
[13] Fixed safety gate
23
Safety
4 Safety equipment functions

To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.
4.1 EMERGENCY STOP buttons for plant shutdown

The EMERGENCY STOP buttons are located on the control panel of the injection molding
machine and - depending on the machine type - in the following areas:
on the rear side of the injection molding machine
on the robot manual control unit
at the safety gate of a safeguard
inside a safeguard
When an EMERGENCY STOP button is activated, the injection molding machine motors
immediately switch OFF. Message:
Emergency-off
Cause An EMERGENCY STOP function is active, e.g. EMERGENCY STOP

button pressed, rear safety gate open
Effect The cycle, motors and movements stop immediately.

The alarm lamp flashes.
Restarting after an EMERGENCY STOP

1. Make sure no dangerous situations exist.
2. Release the EMERGENCY STOP button by turning it clockwise.
3. Activate the Program Interruption switch to acknowledge the alarm.
4. Switch on the motors.
Note!
The EMERGENCY STOP function is active in each mode of operation!

Safety
4.2 Functioning of the safety gates

Opening a safety gate blocks all hazardous movements and a corresponding message is dis-
played on screen.
Clamping unit safety gate x open
Effect All machine movements are blocked
Remedy Close the safety gate.
Clamping unit safety gate interrupts cycle
Cause Safety gate has been opened in the automatic mode
Effect Cycle interruption, motor standstill, heating reduced, alarm lamp
Remedy Close the safety gates, move the machine into the start position and
start the cycle again.
Depending on the protection type, opening the rear safety gate on the clamping unit causes an
EMERGENCY STOP switch-off, or executes the same function as the operator side safety
gate.
When a safety gate on the injection unit is opened, the following message appears:
Nozzle safety gate open
Effect Blocks all injection unit side movements and close mold, cycle stop.
Remedy Close the nozzle side safety gate
In semi-automatic or manual mode, the following message appears if the safety gates have
their own monitoring modules:
Clamping unit safety gate x open-close
Cause The safety gates must be checked:

Injection unit-side safety gate, at least every 7 days.
Non operator side safety gate, at least every 30 days.
Effect Blocks all machine movements in manual mode, no motor start and
cycle start possible.
Remedy Check for correct switching sequence by opening and closing the
safety gates.
25
Safety
4.3 Closing area acknowledgement (as of DUO 800)

For safety reasons, the control unit blocks the movements of the mold and center plate after
the safety gates are closed.
ATTENTION: Closing area acknowledgement!
Help Area free
DANGER!
Danger of fatal injury due to moving components and high-pressure

injection!
Check that no persons are located in the closing area before acknowl-
edgement.
Settings, see the Var monitor group ’SafetyGate’.
4.4 Automatic safety gate

A drive supports convenient, automatic opening and closing of the clamping unit safety gate.
This is a big advantage particularly in semi-automatic mode, with manual take-off and insert-
placing of injection molded parts.
Push buttons:
Close safety gate
Opening safety gate
When the drive is switched off, move the safety gate by hand only.
When the drive is switched on the safety gate is moved with the push buttons.
Electric safety gate

Screen switch for manual or electrical operation.

Safety
Screen switch for manual or electrical operation.

Safety gate activated in sequence
Opening stroke in semi-automatic mode
+
Safety gate 1 brake opening
final position Braking limit switch Safety strip
closed
open
controller release
Direction Open Close

In semi-automatic mode, safety gate movements can be programmed in the machine
sequence.
The safety gate opens at the programmed position and waits for the start key. When the
start key is pressed, the safety gate closes and the cycle starts when the key is pressed
again.

In semi-automatic mode, the safety gate opens with an adjustable opening stroke.
Program the movements of the safety gate as usual in the machine sequence.
Note!
Automatic movements of the safety gate is possible only in semi-automatic mode.
Semiautomatic mode
Safety gate movements can be programmed in the machine sequence.
In semi-automatic mode, the safety gate opens at the programmed position and waits for the
start button. When the start button is pressed, the safety gate closes and the cycle starts when
the button is pressed again.
Sequence example:
Open safety gate with open mold and ejector advanced.
Open mold
700,0 mm
Advance ejector
95,0 mm
Open
Close
Retract ejector
70,0 mm
27
Safety
Safety edges are fitted to the safety gate to protect persons.

When the safety edge is actuated, the safety gate movement stops and the following message
is displayed:
Safety gate - safety strip - actuated
Effect No automatic mode, movements on the clamping unit and on the

injection unit side blocked. After a short standstill time the safety gate
slowly moves in the opposite direction
Remedy Safety edge relief
Close safety gate
Cause The safety gate is not closed when switching from manual to electri-
cal mode
Effect no cycle start
Remedy Close the safety gate in the manual mode of operation
4.5 Safety guarding

To safeguard the danger zone in the plant, a safety guard that contains a protection door for
entering the danger zone has been attached to the machine.
The safety guarding is generally connected to the injection molding machine in place of the
rear safety gate of the clamping unit, optionally operator side possible.
Example: safety guarding with protection door
2
1
0 3
1
4
I T
QU
30
XH
[1] EMERGENCY STOP button inside

[2] EMERGENCY STOP button outside
[3] Access request key with lamp

Safety
[4] Acknowledgement key with key-operated switch
WARNING!

injection!
The person inside the safeguard must always possess the key from the
key-operated acknowledgement switch in order to prevent accidental
acknowledgement of safeguards, which would cause the machine to
restart.
Do not acknowledge the safety guard until the danger area is clear of
personnel and foreign bodies.
With this safety guard, only vertical and lateral removal are possible. However, lateral removal
is only possible in injection molding machines without tie bars when the rear safety gate of the
clamping unit is open. (optionally also on operator side). The protection door in the safety
guard takes on the function of the rear safety gate of the clamping unit.
Entering the hazardous area

1. Actuate the access demand button to unlock the protection door (button flashes). The
injection molding machine stops at the end of the cycle.
2. The access request key lighting up indicates that the protection door has been unlocked
and enabled for opening.
3. Before opening the protection door, remove the key from the key-operated acknowl-
edgement switch and take it in with you.
Movements of the injection molding machine are blocked when the protection door is
open.
4. After leaving the danger area, the operator must acknowledge the protection door with
the key-operated switch immediately (within 5 seconds) after closing the door, this then
locks the protection door.
5. The plant continues processing the program after the start key is actuated.
Unlocking the protection door

When the machine is switched on and the protection door is locked, press the access demand
button to open the protection door. The protection door automatically unlocks when the
machine comes to a standstill.
The protection door automatically unlocks in case of an emergency stop after a standstill of the
machine and when the machine is switched off.
Pluggable safety gate

The safety guarding and protection door are connected to the injection molding machine via a
male connector instead of the rear safety gate on the injection unit (optionally also operator
side).
Attach the rear safety gate of the clamping unit

For example, the end of arm tooling can be changed while the injection molding machine is in
production When the safety gate on the clamping unit is connected, the protection door in the
safety guarding has no function.
1. Disconnect safety guarding with protection door.
2. Connect and close the safety gate of the clamping unit.
29
Safety
Connect safety guarding with protection door

For example, for shared automatic mode of the injection molding machine and the robot.
1. Disconnect and open the rear safety gate of the clamping unit.
2. Connect safety guarding with protection door.
3. Open/close the protection door and acknowledge.
Alarms and messages

An acknowledgement must occur after switching on the control voltage The following message
is displayed until you acknowledge the protection door:
Open-close-acknowledge safety gate x;

Acknowledge safety gate x
Effect Movements of the injection molding machine are not possible.
Remedy Open - close safety gate and acknowledge within 5 seconds using
the key-operated switch
The acknowledgement must occur within 5 seconds of, but not within 0.05 seconds after clos-
ing the protection door.
You are not permitted to press the acknowledgement key for too long (maximum of 10 sec-
onds). If these conditions are not fulfilled, the following message appears:
Safety guarding x acknowledgement time exceeded;

Clamping unit safety gate x (SIP3): acknowledgement key actu-
ated too quickly;
Clamping unit safety gate x (SIP3): acknowledgement key actu-
ated for too long
Effect Protection door not acknowledged
If the rear safety gate of the clamping unit is closed when the safety guard is connected, the
following messages appear:
Clamping unit disconnected safety gate x not open
Effect Automatic operations with machine not possible.
Remedy Completely open the rear safety gate of the clamping unit.

Safety
4.6 Step safety

Step-on plates in the clamping unit area prevent machine movements when a person is within
the machine's safety gates.
WARNING!
Danger of fatal injury if safety equipment is not cleaned!

Keep safety floor plates (plate elements)clean at all times (e.g.: remove
sprue, injection molded parts, etc.). Parts jammed in the gap between
the steps can impact the functionality of the steps.
Clearing must only be carried out when the machine is switched-off.
Clean the step-on plates at each routine maintenance.
The following actions are blocked when step safety is actuated:

Automatic cycle start
Mould closing, mould opening
Injection, plasticizing
Advance nozzle
Ejector, core, and mold shut-off nozzle movements
Open and close safety gate electrically
In plants with robot, all robot movements (robot motors must switch off)
The number of step-on plates (= area) depends on the machine type and machine size.
Example: DUO 1000 with 5 zones; Zone 2 marked as defective in color

Step safety
Step-on safety 1 deactuated

Starting the step safety test manually
When step safety is actuated, the following message appears:
31
Safety
Step safety - area x active
Cause: The step safety between the mold halves or between the safety gate
and mold was triggered.
Effect: Mold closing, mold opening, injection, plasticizing, advance nozzle,

movements of ejector, core and mold shut-off nozzle, and opening/
closing electric safety gate are blocked.
Remedy: Relieve safety floor plates. If needed, check limit switches.
Note!
For step safety maintenance and testing, see ’Service Manual - Maintenance of safety equip-
ment chapter’.
4.7 Mechanical closing safety

The purpose of the mechanical closing safety is to prevent the moving mold fixing platen from
closing.
If the safety gate is open, the mechanical closing safety will be locked.
If an attempt is made to move the clamping unit when closing safety is engaged, the following
message will appear:
Mechanical closing safety x moved in
Cause Mechanical closing safety not moved out.
Effect No mold movement or mold height adjustment possible and cycle

start will be disabled.
Remedy Closing safety is actuated by opening and closing the safety gate.
In an EMERGENCY STOP a jamming of the closing safety may occur. This jamming may pre-
vent the closing safety to be moved out after clearance of the EMERGENCY STOP. Proceed
as follows to free the closing safety:
1. Switch to Set-up
2. Press the key Mold opening and the Safety key at the same time in order to open the
mold a short stroke +
3. Open/close the safety gate on the clamping unit.
Note!
For mechanical closing safety maintenance, see ’Service Manual - Maintenance of safety
equipment chapter’.

Safety
5 Additional equipements
The installation of additional equipment is only permitted with the permission of ENGEL.
If additional equipment is attached to the machine without ground support, a new evaluation of
the risk of tipping must be implemented.
ENGEL is only responsible for the cooperation of the machine with additional equipment if the
interfaces have been designed by ENGEL.
Sockets on the injection molding machine may only be used for the specified additional or
peripheral equipment.
Robot interface / Automation to Euromap 67 or 12

Before connecting and using an interface, risk assessment must be performed by ROBOT
vendor!
WARNING!
Danger due to missing safety gates!

If safety gates are removed to support machine operations with periph-
eral equipment (e.g. conveyor-belts, stacking devices, etc.), the user
company must implement safety measures that do not impact on safety
levels!
If the machine is then operated again without peripheral equipment,
ensure the original safety gates are restored to their original state.
The installation of additional equipment must not reduce the view into dangerous machine
areas, not must it hinder access to workplaces specified in the operating manual.
In a case of damage, ENGEL does not assume liability of any kind!
6 Mounting aid
Machines with material hopper must be equipped as per EN 201 with secure access means or
the user must provide mobile, secure access means for the machine. We recommend that a
mounting aid offered by ENGEL be used.
Proper Use:
The mounting aid is only suitable for manual filling of the material hopper in horizontal standard
injection molding machines without a robot and without additional equipment. Free usage is
prohibited!
WARNING!
Danger of crushing due to moving components!

Unauthorized, non-permanent mounting aids can allow staff to reach
into dangerous areas of the machine.
Only position the mounting aid up to the position marked on the injec-
tion molding machine by a sign. It must be impossible to reach into any
danger areas of the machine.
Maintain safety distances as per EN ISO 13857.
33
Safety
Check the safety distances as per EN ISO 13857 of the mounting aid and respective machine
before use and mark the correct position with the sign.
Example: ENGEL mounting aid for manual material feed
The mounting aid on the front side of the machine

must be moved to the position marked by a sign and
fixed in place by locking the wheels.
The mounting aid must be present at the site prior to
start of production.
WARNING!
Danger of falling due to oil and spilt granulate!

Keep mounting aid clean and do not use if contaminated.
7 Behavior in case of fire
1. Keep calm
2. Alert the fire department
3. Switch off the machine at the main switch
4. Alert all persons in the danger zone
5. If possible, close all fire doors
6. Switch of any venting and/or air conditioning units
7. As soon as possible, contain the fire with an approved fire extinguisher
8. Provide assistance and direction to anyone actively involved in fighting the fire
Use an abc class fire extinguisher

This is most suitable due to its versatility compared with other extinguishing agents.
Be familiar with the instruction label attached to the fire extinguisher.
Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.

Safety
DANGER!
Danger of fatal injury due to electric shock!

Use of water, foam or D class fire extinguishers is prohibited.
When using ABC powder fire extinguishers keep a distance of at least
one meter to electrical equipment.
Note!
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:
at your local ENGEL dealer/subsidiary, or

contact the nearest ENGEL works
35
Safety
8 Rescue actions
Perform the following rescue actions to release trapped persons from the mold area;
note that accidents of this kind can only occur in case of gross misuse or if you disable
vital safety devices!
1. 2 persons are required to provide first-aid (both must be skilled in the use of the injection
or compression molding system).
2. One of the two rescuers must mechanically secure the machine against motions, such
as lowering or clamping, that would further endanger the victim or rescuers (moving
mold mounting plate, core-pull, ejector).
3. The second rescuer must manually move the machine to a position where the victim
can be freed.
4. Leave the danger area (mold area) with the person you have rescued.
5. Give first aid.
6. Call a paramedic.

Safety
9 Safety conformity pursuant to Machine Directive

Machines are delivered safety-compliant with CE mark or incomplete for incorporation in a
total system.
9.1 Not safety-compliant machine

The declaration of incorporation is located in the ’Service Manual Machine’ in Chapter ’Draw-
ings and Certificates’.
WARNING!
Danger of fatal injury due to missing protective equipment!

Starting up the incomplete injection molding machine is prohibited.
Install the injection molding machine in the total system according to
the assembly instructions and safeguard the danger zone.
You are not permitted to operate the system until an authorized expert
has type-approved the machine and confirmed that safe operations are
given, and until a declaration of conformity has been presented, and a
CE sign has been attached to the system.
Example of a system
3 4
[1] Injection molding machine

[2] Conveyor belt with protective tunnel
37
Safety
[3] safety guarding with protection door

[4] Robot
Assembly instructions
WARNING!
There is a risk of fatal injury in the case of incorrect assembly!

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

Safety
9.2 Safety-compliant machine

The EC declaration of conformity is located in the ’Service Manual Machine’ in Chapter ’Draw-
ings and Certificates’.
The machine is safe to operate and ready for operation after setup and start up by an autho-
rized person.
WARNING!
There is a risk of fatal injury in the case of incorrect assembly!

The injection molding machine may only be assembled by authorized
persons.
controls.
Observe the safety instructions in the manual.
All supplied safety gates must be mounted prior to starting up.
The following conditions must be fulfilled to enable the injection molding machine to be prop-
erly assembled without compromising the safety and health of persons:
Suitable means of transportation and sturdy mounting aids.
Ambient conditions see ’Service Manual Machine’.
Implement transport, setup and connection as described in the ’Service Manual
Machine’.
39
Safety

Installation and commissioning
Check the delivery immediately on arrival:

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

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

Minimum: 20%
Maximum: 80%
Altitude
A performance loss of 1% per 100m (330 ft) above sea level must be included with installation
locations that are higher than 1000m (3300 ft) above sea level.
Electromagnetic compatibility
Must correspond to the EC EMC directive (2004/108/EC)!
Must comply with the North American Standard NFPA79 2007!
Cooling water
Maximum: 20 °C (68 °F)
Use clean cooling water only [See Cooling water on page 65.]
41
1.1 Foundations
Consult a construction expert (expert builder or structural engineer) to make sure that the
foundations fulfill the following requirements:
Load-bearing capacity of the existing shop floor sufficient?
Establishment of a foundation required?
Note!
Observe details in foundation plan!
Space requirements: In order to work on the machine, you must ensure that access is
possible from all sides!
Machine weight
Machine pedestals
Positions
Maximum height adjustment
External diameter

2 Transportation
WARNING!
Danger of fatal injury from floating loads!

Floating load hazard!
Transportation must be performed by skilled staff familiar with transpor-
tation of machines.
Use lifting gear and cables with sufficient load-bearing capacity. For weight refer to type
plate on machine or to Plans and Protocols chapter (technical data, foundation plan).
Only use the marked lifting eyes for transportation.
The injection molding machine must be lifted and transported horizontally (longitudinally
and diagonally). Adjust lifting gear length accordingly.
Make sure the cables are of sufficient length (taking the maximum spread of the cables
on the crane hooks into consideration 60°).
Before lifting the machine, remove any hindering components and use lifting gear with
edge protection if contact with the edges of neighboring components is possible.
Before lifting the machine, check the routing of the cables from the lifting eyes to the lift-
ing gear.
Clamping unit and injection unit must be secured against possible axial movement by
using the transport safety brackets provided. The rod bearings must be fully extended.
The clamping unit should preferably be moved to the maximum mold height.
43
Transport sketch for clamping unit, example for DUO

Machine support pad - clamping unit

1. Position the machine pedestals according to the foundation plan.
Machine frame
Leveling bolts
Machine mount
2. Place the clamping unit on the positioned machine pedestals.

3. For basic adjustment, align the clamping frame using the leveling screws of the machine
pedestals in the longitudinal and traverse directions. Carry out measurements on the
machine frame using a precision water level and a level bar.
WARNING!
Danger of crushing by moving components that extend beyond the

machine frame!
Keep a minimum gap of 500 mm (20 in) between the rear position of the
moving injection unit and any fixtures. This clearance must be
measured at maximum nozzle and plasticizing stroke.
Transport sketch injection unit 16050 - 23050
min. 500 mm
(min. 20 in)
45
Machine mount
1. First screw the counter nuts and the washers onto the adjusting spindles.
2. Lubricate the adjusting spindles and insert into the machine frame bores from above.
3. Screw the machine pedestals to the machine frame from below using the adjusting spin-
dles.
Adjusting spindle
Counter nut with washer
Machine frame
Machine mount
WARNING!
Danger of fatal injury due to missing safety gates!

Removal of a safety gate may be necessary due to transport. The sys-
tem may only be operated after the safety gates are correctly mounted!

3 Connection of injection frame and closing frame

1. In order to connect the frames of the clamping unit and the injection unit, bring the injec-
tion unit to the correct position.
2. Use the centering pin to align the injection unit.
3. Bring the threaded spindle of the clamping unit frame together with the consoles of the
injection unit frame.
Injection frame
Console
Threaded spindle
Centring bolt
Threaded spindle
Closing frame
Injection frame
4. Screw the injection unit frame to the threaded spindles and place them on the machine
pedestals. Then loosen the threaded spindles somewhat.
47
5. For basic adjustment, use a ruler on both sides to align the injection unit frame to the
same height.
Milled areas
Ruler
6. For basic adjustment, level the injection unit frame horizontally in the longitudinal direc-
tion. Carry out measurements on the guide rails using the precision water level.
7. Connect the hydraulic hoses and electrical connections of the injection unit to the
clamping unit.
Hydraulic hoses
Injection unit
Clamping unit
4 Remove the transportation safeguard

CAUTION!
In the case of ocean transport, all motor pump combinations with a 3-

way pump are fixed.
Before commissioning, remove the support!
Support
4.1 Remove the clamping unit transport safety brackets

The procedure for dismantling transport safety brackets does not apply to clamping units that
are transported in modules (clamping unit frame, stationary mold fixing platen, tie-bars, mov-
ing mold fixing platen, etc.)!
Spacers are mounted between the movable/stationary mold fixing platen and the transport
safety brackets on the locking nuts; these serve to provide stable transport.
49
Distance piece
Locking nuts
Distance piece
Procedure for dismantling transport safety brackets:

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

2. Remove the screws from the spacer only on the movable mold fixing platen. The spacer
can be removed using suitable lifting gear only after commissioning.
Moving mold fixing platen
Distance piece
Screws
Note!
If the injection molding machine is transported again, the transport safety brackets must be
reattached.
5 Leveling the injection molding machine

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

[2] Injection unit measuring range
[3] Machine pedestal (for position of all machine pedestals see foundation plans)
51
Measuring equipment: Precision spirit level and level bar for latitudinal measurement.
Precision spirit level bar
Leveling:
1. Check current machine level:
Measuring area clamping unit side: Longitudinally and latitudinally over both guide
rails for the clamping unit side moving platen.
Measuring area injection unit side: Measure longitudinally and at 90° latitudinally
over the injection unit guide rails.
2. Use the adjusting spindles on the machine pedestals to level the injection molding
machine. Starting on the clamping unit side, first in longitudinal direction, and then lati-
tudinally.
A deviation of max. 1 sub-graduation line on the precision spirit measure is permis-
sible.
All machine pedestals must rest flush against the floor and exert equal force on the
floor.
Repeat the process if needed.
3. Tighten the counter nuts on the machine pedestals.
Note!
Level after commissioning; check again after a production time of approx. 4 weeks and adjust
if needed.
Repeat leveling if the machine leaves the installation position during production.
If you set the machine up at a different position later, it makes sense to number the machine
pedestals to be able to use them at the same positions on the machine frame.
If machine pedestals show signs of wear or defects, replacement of all pedestals on the clamp-
ing or injection unit is recommended (to avoid the need to repeat leveling at frequent intervals).

Leveling:
1. Loosen the counter nuts of the threaded spindles between the frames of the injection
unit and the clamping unit.
2. Dismantle the covers from the machine frame on the clamping unit.
3. Use a precision water level to check the clamping unit in longitudinal direction.
Tolerance 0.2 mm/m (0.00787 in)
Precision water level
Cover plates
4. Use the leveling screws on the machine pedestals to longitudinally level the clamping
unit.
5. For the transverse measurement, mount the cylinder pins (which are in the accessories
box) on the stationary and moving mold fixing platen.
2 Cylinder pins per mold fixing platen
6. Attach a level bar and a precision water level for the transverse measurement. Toler-
ance 0.2 mm/m (0.00787 in)
2 Cylinder pins per mold fixing platen
level bar
7. Use the leveling screws on the machine pedestals to level the clamping unit in the trans-
verse direction.
53
8. Use the adjusting spindles on the machine pedestals to level the injection unit in the lon-
gitudinal and transverse directions. Measuring range longitudinally and 90° transversely
over the injection unit guide rails.
9. Tighten the counter nuts on the machine pedestals.
10. Tighten the counter nuts of the threaded spindles between the frames of the injection
unit and the clamping unit.
Note!
Level after commissioning; check again after a production time of approx. 4 weeks and adjust
if needed.
Repeat leveling if the machine leaves the installation position during production.
Check whether the machine is level once a year!
If machine pedestals show signs of wear or defects, replacement of all pedestals on the clamp-
ing or injection unit is recommended (to avoid the need to repeat leveling at frequent intervals).

5.1 Alignment of the stationary and moving mold fixing platen

Procedure:
1. Mount the supplied test mandrels on the stationary and moving mold fixing platen.
2. Use a precision water level to check the stationary and moving mold fixing platen
Maximum deviation: 0.2mm/m (0.00787 in)
Test mandrels
2.1. Variants from DUO 350 to 2700

Horizontal alignment of the mold fixing platens with the cylinder pins is a prerequisite for
exact tool centering. [See Leveling the injection molding machine on page 51.]
Test mandrels
55
3. Use a frame water level to check the vertical alignment of the stationary and moving
mold fixing platen.
Frame water level
4. Adjust the stationary and the moving mold fixing platen when larger deviations are at
hand.

Procedure for adjusting the moving mold fixing platen:

1. The height and vertical alignment of the mold fixing platen is adjustable via the wedge
shoes from DUO 500 and higher.
Wedge shoes
2. The horizontal position of the platen can be set by removing the feeler gauge on one
side and inserting them on the opposite side.
Spy plates
3. Check the platen parallelism using an inside micrometer.

Maximum tolerance 0.3 mm (0.0118 in) for DUO 350 - 600.
Upper measuring points
Inside micrometer
Lower measuring points
57
4. Check the displacement between the stationary and moving mold fixing platen using a
straight-edge. 0.2 mm/m (0.00787 in).
Test mandrels
Knife-edge
straight-edge
4.1. Variants from DUO 350 to 2700
Knife-edge
straight-edge
Test mandrels
5. Check the lateral guide using a feeler gauge.

The tolerance between the lateral guides of the moving mold fixing platen and the guide
frame may not be more than 0.2 mm/m (0.00787 in).
Feeler gauge
Guides
5.2 Floor anchorage
Note!
After setting up the clamping unit, the floor anchors should be mounted by the customer to
prevent the machine from moving.
Floor anchors fitted as of DUO 800!

[1] Machine frame

[2] Distance piece
[3] Fixing screws
[4] Console
[5] Machine mount
5.3 Ventilation pressure pad
Note!
At the first start-up of the injection molding machine it must be run with the pressure pads on
maximum and minimum position of the tiebars in order to vent the pressure pads.
59
1. Close mold until position = 0 mm

2. Do not lock locking nuts.
3. Using each tie-bar, individually move through the minimum and maximum tie-bar posi-
tions 2-3 times.
5.4 Cleaning after installation

Use cleansing agent (e.g. paraffin) to remove the anti-corrosive protection applied at the works
on brightwork (e.g. rails).
CAUTION!
Danger of damage to machine components!
Use only soft cleaning rags for cleaning; never use wire wool or hard objects.
Clean all Plexiglas covers. Using warm water when applying a mild cleaning agent and
a soft cloth or sponge. (Never use concentrated disinfecting agents or solvents, such as:
Sagrotan, Lysoform, ethyl alcohol, acetone or other liquids containing alcohol under any
circumstances)
Clean grease nipples to prevent dirt entering grease cavities during lubrication.
Carefully clean all guide rails.
After cleaning, lightly oil the exposed metal areas.
6 Safety guarding assembly instructions

The safety guarding must protect the danger zone.
WARNING!

Transportation must be performed by skilled staff familiar with transpor-
tation of machines.
Transport of the protection door

You can transport the protection door in two ways:
Eyebolt (M8)

The safety guarding must be anchored to the injection molding machine and the floor.
Screws (M8)
61
7 Connecting
7.1 Electric connections
WARNING!
Danger of fatal injury due to high voltage!

A qualified electrician is required to connect the machine to the mains
power supply.
Always observe your power distributor's regulations.
Pay attention to:

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

WARNING!
Danger of fatal injury due to high voltage!

When fitting additional equipment to the injection molding machine (e.g.
conveyor-belt, dryer etc.) ensure good conductivity of connection to
electric potential of machine! (Equipotential bonding conforming to EN)
63
Check the direction of rotation of the pump drive motors:
Hydraulic oil filling must be guaranteed!

Disconnect all the fuse disconnectors of the pump drive motors.
Afterwards press in the fuse isolating links one after the other.
Only for filter/cooling motor,
Briefly switch the motor on/off,
Check direction of rotation of the motor (Observe arrow direction on the motor),
In case of need change the phases.
Now press the fuse disconnectors of motor 1 and check the filter/cooling motor.
Also check the direction of rotation of the other motors in the same manner.

7.2 Cooling water

Cooling with flowing water from the public supply network is not recommended. Hard water
can cause deposits or corrosion and damage the motor and cooling system.
Depending on the machine type, cooling water may be required for:
Oil cooling, for cooling hydraulic oil, for hydraulics unit
Flow controller (barrel infeed area, mold heating)
Temperature control devices
Water-cooled servomotors
A flexible connection to the supply line is required (use appropriate hose connectors). Note
connectors for feed and return flow!
Observe correct positions and connection dimensions for the cooling water connections in
foundation plans.
Note!
The cooling water values in the following overview are recommendations.
If the water temperature is exceeded, the integrated monitoring can cause a production inter-
ruption.
Water temperature:
Water infeed temperature max. 20 °C (68 °F) for water-cooled servo-motors
Water infeed temperature max. 25 °C (77 °F) for standard machines
Water infeed temperature max. 30 °C (90 °F) for machines with larger oil cooler
Input pressure 3-5 bar (44-73 psi)
Pressure differential between flow and return min. 1.5 bar (22 psi)
Cooling water quality:
The water must be clear, colorless and inodorous as well as free from algae, germs, fungi,
bacteria, iron, manganese, hydrogen sulfides, floating matter, suspended matter and sedi-
ments.
The values indicated in the table are basic recommendations without guarantee.
We cannot give any warranty concerning the durability of parts that come into contact with
cooling water as the aggressivity of the water depends on many factors.
Note!
If the following values are unknown, or not adhered to, consult a hydro-technology expert to
obtain detailed analysis. The consultant will be able to suggest suitable approaches as
needed.
65
Overview - Cooling water values: (recommendations without warranty!)
Corrosion resistance
These values are provided as a guideline.
Water constituents Concentration
Electric conductivity maximum 500 µS/cm
Iron (dissolved) maximum 10mg/l
Manganese (dissolved) maximum 1 mg/l
Chloride* maximum 80 mg/l
Free carbonic acids* maximum 0 mg/l
Sulfate maximum 200 mg/l
pH value maximum 6 - 8
Alkalinity maximum 2 - 18 dH
Total hardness maximum 5 - 14 dH
NH3 maximally 2 mg/l
Oxygen maximally 2 mg/l
Sulfite, free chloride* 5 mg/l
Free (aggressive) carbonic acids 20 mg/l
Oil maximum 1mg/l
Permissible grain size of foreign 0,1 mm (0.0039 in)

bodies
Turbidity 0 mg/l
Organic elements
Temperature increase motor maximally 15 °C (59 °F)

cooling (for servomotors only)
* Depends on temperature maximum 60°C (140 °F) and pH value
7.3 Cooling water consumption

The values are a guideline to how much m³/h water is required for a machine without mold.
7.4 Cooling water consumption

The values should be a guideline to how much water is required for a machine without mold.
7.5 Throughput controller

The flow meter is used for the mold cooling and the infeed zone of the barrel. The flow meter
enables precise volume control with temperature control for each mold cooling circuit. The
coolant temperature can be max. 100 °C (212 °F) and max. 10 bar (145 psi).

Example: 8x flow meter

1 2 3 4
5
6
9 8
[1] Sight glass

[2] Display of flow rate with float cone
[3] Marking ring for flow rate adjustment
[4] Cooling water outlet connection
[5] Handwheel for shut-off valve
[6] Handwheel for regulating valve
[7] Cooling water inlet connection
[8] Connection for mold cooling circuit return line
[9] Connection for mold cooling circuit flow line
Throughput con- Cooling water Water flow rate per circuit

troller inlet - outlet con-
nection
Series 101 3/4 inches 10 l/min (158.5 gal/h (US))
Series 301 5/4 inches 30 l/min (475.5 gal/h (US))
Note!
The following parameters must be complied with otherwise damage to the flow meter or injury
to operating personnel can occur:
67
Temperature Max. pressure
40 °C (104 °F) 10 bar (145 psi)
60 °C (140 °F) 8 bar (116 psi)
80 °C (176 °F) 6 bar (87 psi)
100 °C (212 °F) 4 bar (58 psi)
Flow meter connection :
A flexible connection to the supply line is required (use appropriate hose connectors). Note
connectors for feed and return flow!
Observe correct positions and connection dimensions for the cooling water connections in
foundation plans.
Mold connection:
The flow meter-mold connection hoses are not part of our scope of supply.
Commissioning:
Turn the handwheel for shut-off valve counter-clockwise until water flows through the sight
glass.
Setting the flow rate:

Turn the handwheel for the regulating valve counter-clockwise until the floating cone shows
the required flow rate in the sight glass.
7.6 Compressed air connection

For machines with pneumatically actuated equipment, an air filter unit is required.
WARNING!
Danger of injury due to damage high-pressure lines!

All pipelines on the plant must be checked for their work-safe state at
least quarterly.
CAUTION!
Danger of damage due to air valves clogging!

Use only oil-free compressed air. (For compressed air quality see follow-
ing specifications)
The compressed air line must be of the same dimensions as the maintenance unit it services.
If a smaller line is used, pressure to the system may be inadequate.
The installation direction is marked with an arrow (flow direction).

Supply pressure max. 10 bar from the unit to the maintenance unit
Max. (1 MPa)
max. (145 psi)
Operating pressure to be set 6 bar from the maintenance unit up to the

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

[2] Manual shut-off valve
[3] Manometer
[4] Filter tray
[5] Display for the condensate level
(Maximum fill height)
[6] Condensate drain (orange button)
The pneumatic system must provide a compressed air quality that complies with the following
specification:
ISO/DIN 8573-1 Quality class Values
Residual oil content 4 5 mg/m³
Residual dust content 3

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

(at pressure dew point DPT) 3° C
Installation:
69
If possible, mount at the point with the highest pressure and the lowest temperature (near the
consumer).
At the connection observe arrow for flow direction on controller housing.
Observe temperature and pressure limits. Build in reservoir axis vertically.
Close the opposite, not used connection.
Commissioning:
Lift the handwheel from its latched-in position up to the stop, then turn to the left, and allow to
latch in again. Switch on the compressed air supply.
Setting of the operating pressure:

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

Lift the handwheel from its latched-in position and turn counterclockwise until the operating
pressure has dropped below the new set value, then set the new pressure by turning clock-
wise, and allow it to latch in again.
See also maintenance instructions in chapter:. [See Compressed air unit on page 180.]

8 Commissioning
Before switching the machine on, check that all transport safeguards have been removed, and
that all installation and connection tasks have been performed correctly.
WARNING!
Failure to follow instructions for commissioning may lead to fatal injury!

Do not commission the injection molding machine unless you have
ensured that:
All fixed and moving covers on the injection molding machine have been correctly
screwed down and are closed.
The plant is ready for use, and complies with safety regulations.
There are no persons in the machine's danger area.
Note!
As a general recommendation, make a backup copy of Harddisk0 for initial commissioning. If
needed, you can then copy the backup to an ENGEL-approved CF type (currently Toshiba
THNCF256MDGi) and insert [See Firmware - Update on page 187.].
8.1 Starting the motor

After switching on the control voltage, and booting the control unit, you can now start the pump
motors with safety gates closed.
Motor start-up sequence:

1. Filter/cooling motor (not on small-scale machines)
2. A start-up impulse from the control unit starts the pump motor at ’Stand-by output’ (e.g.
pressure 30bar, volume 30%)
Multiple motors will always start one after the other.
Pumps on motors that are running must show stand-by pressure. Pumps for motors that
are to be started must be below the max. pressure for motor start.
3. The motor start button lights to indicate that all motors are delta connected.
4. Stand-by operations commence after the ramp-up circuitry of the motors has switched
from star to delta. An oil preheating program starts if the oil temperature is too low.
Pump overview
Info Panel
Pump Pressure Volume Pump on motor
+
Volume display for certain machine types only.
71
Note!
If you press a pushbutton, without waiting for motors to enter delta phase, the motors stop
again.
8.2 Connecting the injection unit to the stationary mold fixing platen
Procedure:
1. Attach the nozzle carriage unit of the injection unit to the couplings on the stationary
mold fixing platen using the bolt.
Bolt
Coupling
Nozzle carriage cylin-

der

73

Setting up for injection
The barrel, screw and nozzle need to be adjusted to match the injection mold for some injec-
tion molding processes.
WARNING!
Danger due to hot barrel and pressurized molten material!

Danger of serious eye injury and burns to skin.
Observe the following items:
Wear suitable protective clothing and face protector.
Ensure that the process material is pressureless.
Note!
Observe the following, before working on the nozzle, screw, and plasticizing barrel:
1. Heat barrel to operating temperature.

2. Clean the barrel with a suitable cleaning agent and purge.
1 Nozzle centricity
Nozzle centricity must be checked at maintenance interval 3, after leveling the machine, or
replacing the barrel.
Results of nozzle centricity check at manufacturing works

Barrel: temperature approx. 200° C (390° F)
Nozzle position: At same level as mounting surface
Measuring equipment: Calipers, precision spirit level
Measuring position: Vertical and horizontal from nozzle opening to centering bore on
mounting platen
Centering tolerance: max. 0.2 mm (0.01 in)
75
3
4
[1] Measuring positions horizontal
[2] Measuring position vertical
[3] Mold mounting surface
[4] Nozzle
Readjustment is required when:

The nozzle position is outside of centering tolerance.
The nozzle moves laterally or vertically when building up contact pressure at the injec-
tion mold.
Nozzle set-up procedure injection units 16050
The injection unit must be at a central position for adjustment without pressure build up.
Vertical centering of the nozzle:
Piston rod
Counter nut and

Counter nut
Adjusting screw and fix-

ing screw

1. Loosen counter nut.
Adjusting screw
Counter nut
2. Remove the fixing screws and counter nuts from the operator side and the non-operator
side of the injection unit.
Counter nut
Fixing screws
Adjusting nut
3. Remove the adjusting screw.
Adjusting screw
4. Place the precision water level parallel and perpendicular to the piston rods of the injec-
tion cylinder.
level bar
77
5. Turn the counter nuts and the barrel support to bring the injection unit into the horizontal
position.
6. Tighten the fixing screws, counter nuts and the adjusting screw.
7. Advance and retract the nozzle several times.
8. Check nozzle centering.
9. If necessary, repeat the adjustment.

Horizontal centering of the nozzle:

1. Remove the fixing screws and counter nuts from the operator side and the non-operator
side of the injection unit.
Counter nut
Fixing screws
2. Remove the adjusting and fixing screws.
Adjusting screw
Fastening screw
3. Position the nozzle horizontally.

4. Tighten the fixing screws, counter nuts and the adjusting screw.
6. Check nozzle centering.
8. Calibrate the piston rod length.
79
Compare and adjust the piston rod length:

1. Advance the nozzle to approx. 10 mm (0.393 in) before the stop (not the max. nozzle
stroke).
Bolt
Coupling
Joint head
Counter nut
Pull rod
2. Uncouple a pull rod by removing the lever bolt.

3. Advance nozzle up to stop (max. nozzle stroke).
4. Loosen the counter nut on the decoupled pull rod.
5. Use the key-receiving surface to turn the pull rod. The bore in the swivel head must be
aligned with the bores on the couplings.
6. Insert the bolts (ensure that they insert smoothly).
7. Tighten counter nut.
9. Advance the nozzle up to the stop.
10. The bolts may not be interlocked at the stop.

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

Drawing [See Mold mounting dimensions on page 207.]
Operator manual section: Setting the clamping unit.
Information by mold manufacturer on mold weight, fixing system, cooling system, mold
heating, media connectors etc.
WARNING!

WARNING!
Danger of crushing with oversized injection molds!

Molds are not permitted to extend over the edges of the machine's mold
fixing platen.
Note!
Danger of damage to mold mounting platen and injection mold!
Use ’set-up’ mode to set the mold height and mount the mold.
Maximum permissible tolerance for mounting surface parallelism on injection mold: 0.1
mm/m (0.001 in/ft).
Make sure the injection mold is adequately fixed!
The fastening screws must reach at least 1.5 x thread diameter into the tapped bore on
the mold fixing platen!
Use injection molds with a minimum side length of (s). Use of molds that are too small
can cause excessive surface pressure.
Calculation of the smallest permissible injection mold side length(s) at the maximum
clamping force:
S 1 = 0.7 x CL 1 (horizontal clearance).

S 2 = 0.7 x CL 2 (vertical clearance).
81
S1
Smallest mold sur-

face
CL 2 S2
CL 1

Correctly and incorrectly mounted molds

Misalignment of the mold halves increases wear and tear, and as a consequence will typically
cause wear and tear on inserts and cores.
As gravity acts in the vertical plane, the vertical alignment of the mold halves is particularly
important. As a general rule, you should attempt to achieve a displacement of less than
0.05 mm (0.002 in). At displacements of 0.1 mm (0.004 in) or more, you will typically hear
some knocking when immersing the guides; some wear and tear of the guide rods can occur.
On large-capacity machines, the displacement can be far higher without causing any prob-
lems.
Wrong Wrong
Correct
3 2
[1] Correctly mounted mold:

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

The ejector side is mounted too low with respect to the nozzle-side mold half.
83
To make best-possible use of a mold, and reduce wear and tear, both mold halves must be
mounted concentrically.
Misalignment of the mold halves increases wear and tear, and as a consequence will typically
cause wear and tear on inserts and cores.
As gravity acts in the vertical plane, the vertical alignment of the mold halves is particularly
important. As a general rule, you should attempt to achieve a misalignment of less than 0.05
mm (0.002 in). At 0.1 mm (0.004 in) or more you will typically hear some knocking on immers-
ing the guides, and some wear and tear of the tie-bars can occur. On large-capacity machines
misalignment can be far higher without causing any problems.
Correctly and incorrectly mounted molds
Wrong Wrong
Correct
3 2
[1] Correctly mounted mold:

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

The ejector side is mounted too low with respect to the nozzle-side mold half.
2.1 Correct crane lifting of molds
WARNING!
Danger from floating loads!

Molds must be mounted only by skilled staff who are familiar with trans-
portation of injection molds.

2.1.1 Attach both mold halves at the same time
1 2 3 4 5
Mold halves pulled Mold halves of Molds not cen- Mold halves Flexible rope or
towards each different weights tered mounted sepa- crane scales
other by rod rately
[1] When fitting both mold halves at the same time, use a rod to connect. Make sure the rod
does not displace the relative center of the two mold halves. If in doubt, mount the two
mold halves separately.
[2] If the two mold halves are of different weights, use a heavy-duty rod, and attach as
closely as possible above the center of gravity of each mold half.
[3] The lifting eye must be exactly above the center of gravity of the mold to allow the crane
to lift it as vertically as possible Always avoid lifting at an angle so that the top is flush
with the fixing platen you need to mount, but with a gap at the under side. Slight skew in
the other direction is not so serious, since you can compensate for this by skewing
slightly by lifting with the crane towards the fixing platen, until you can fit the mold com-
pletely flush.
[4] Do not mount the two mold halves separately as the separating line has to be com-
pletely closed.
[5] Use the crane to provide best possible support to the mold when mounting at center of
the mold fixing platen. You cannot position the mold to a hundredth of a millimeter using
the crane. Make sure you have a flexible connection between the crane hook and the
lifting eye (e.g. synthetic rope). However, crane scales are your best option. Crane
scales will ensure that you lift exactly the weight of the mold, and that the mold can be
mounted on the machine without any gravitational effect. The heavier the mold, the
more important it is to use crane scales. In case of heavy molds, always use crane
scales - use of crane scales for lighter molds is not a disadvantage.
85
2.1.2 Attach each mold half individually
1 2 3 4 5
Individual mold Center the If required, use First mold half Use crane
halves crane above a spacer (with centering scales to mount
mounted off the load, and pin) mounted the second mold
center avoid oblique conventionally half
pull
[1] Attach individual halves exactly above point of gravity to ensure vertical lifting by crane.
[2] When mounting the mold, position the crane exactly above the central axis of the mold
fixing platens. Oblique pull twists the mold and must be avoided.
[3] If the fastening thread is not exactly above the mold's center of gravity, fit a spacer.
[4] Mount the mold half with the centering pin first; this is typically the nozzle side, or the
rotary table side for rotary tables. You can lift the first mold half to be mounted in the nor-
mal way. The mold half is positioned above the centering pin, and there is no need to
take the mold weight into consideration. A flexible rope or crane scales give you an
advantage.
[5] The second mold half to be fitted typically does not have a centering pin, or only sup-
ports rough centering. When the mold closes, and the guide bolts are inserted, the lifting
force exerted by the crane lifting the mold half should be equal to the mold weight as far
as possible. Exerting too little lifting force, or none at all, causes the deadweight of the
mold to act on the guide bolts, and this can cause misalignment and play. In this case,
the mold half mounting position would be too low. Exerting too great a lifting force could
cause the rope to break, or cause the mold half to be mounted at too high a position.
Crane scales give you the ability to lift with precisely the deadweight of the mold half.
Read off the weight value before inserting the guide bolts. After closing the mold, but
before building up clamping and compression force, raise or lower the crane until the
crane shows exactly the weight value shown previously.
The heavier the mold, the more important it is to use crane scales. In case of heavy
molds over 200 kg (440 lb) always use crane scales - use of crane scales for lighter
molds is not a disadvantage.

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

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

In case of heavy molds over 200 kg (440 lb) use crane scales for mounting. Without crane
scales it is very difficult to mount heavy mold halves concentrically to one another. Thus, it may
make sense to finely adjust both halves.
Note!
If you decided to center both halves, you must ensure that both centering pins on the mold
are mutually true to a precision of less than 0.05 mm (0.002 in).
In this case the centering diameters of the two mold fixing platens on the machine must be
exactly true. ENGEL injection molding machine are true to < 0.1 mm (< 0.004 in) coaxially as
a factory standard. If you require greater precision, please specify this requirement with your
order.
Special case for tie-barless machines: If the max. permitted mold tilting torque on the ejec-
tor side (weight of the ejector-side mold half times the distance to the center of gravity - see
instruction manual) is exceeded, an additional support is required.
This consists of 2 additional guide shoes (one each on the operator and non-operator sides)
including supporting brackets which are either fitted to the mold surface on the moving mold
fixing platen, or directly to the moving mold half. The adjusting spindles screwed through the
supporting brackets rest on the top of the guide shoes. They cannot be connected to them as
the moving mold fixing platen, and thus the additional supports, need to lift off the guide shoes
when clamping force is built up. Set the spindles without building up clamping force, at setup
pressure with the mold closed. Only slightly pre-tighten the spindles. The moving mold fixing
platen is not permitted to tilt back. Check platen parallelism if needed.
87
2.2.3 Special applications

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

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

2.3 Correct mounting of molds
WARNING!

Molds must be mounted only by skilled staff who are familiar with trans-
portation of injection molds.
2.3.1 Mounting both mold halves at the same time

Procedure:
1. Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray ).
GREASE
2. Use a rod to connect the mold halves and mount jointly on machine. Align with the mold
fixing platen where the (more exact) centering lug of the mold is located; this is normally
the nozzle side Make sure that you lift the mold vertically with the crane. Always avoid
lifting at an angle so that the top is flush with the fixing platen you need to mount, but
with a gap at the underside. Slight skew in the other direction is not so serious, as you
can compensate for this by skewing slightly on lifting with the crane towards the fixing
platen, until you can fit the mold completely flush.
3. Insert the centering pin into the centering bore on the mold fixing platen. Adjust the mold
rotation using a spirit level if needed, and tighten this side while the mold is still being
supported by the crane.
89
4. Close the moving mold fixing platen in setup mode, and ascertain the mold height.
Leave the mold attached to the crane.
5. Then build up and relieve the clamping force about 3 times, but without opening the
mold; simply relieve the clamping force. Building up and relieving the clamping force
allows for precise mutual alignment of the mold halves in the µm range. Make sure the
lifting force exerted by the crane exactly matches the dead weight of the mold. Then
exert the clamping force.
6. With clamping force built up, tighten the ejector-side mold clamping screws. The for-
mula for minimum reach of screws is: Screw diameter x 1.5. The property class of the
screws should be 8.8 or 10.9 Harder screws can mean danger to the mold fixing thread
especially in the case of cast mold fixing platens. If using a high speed mold mounting
device build up clamping force before moving in the tensioning wedges.
7. Remove the crane and the rod, you can then open and close the mold, and start opera-
tions.
2.3.2 Individual mounting of mold halves

Procedure:
1. Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable

good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray ).
GREASE
2. Move the mold half with the more precise centering pin into the machine and align flush
with the mold fixing platen. This is normally the nozzle side. Make sure that you lift the
mold vertically with the crane. Always avoid lifting at an angle so that the top is flush with
the fixing platen you need to mount, but with a gap at the under side. Slight skew in the
other direction is not so serious, as you can compensate for this by skewing slightly on
lifting with the crane towards the fixing platen, until you can fit the mold completely flush
Insert the centering pin into the centering bore on the mold fixing platen. Adjust the mold
rotation using a spirit level if needed, and tighten this side while the mold is still being
supported by the crane If rotational centering (anti-twist safeguard) is envisaged, it must
also be fitted at this side.
3. Use the crane, and preferably crane scales, to move the second mold half into the
machine, and align precisely with the second (typically ejector-side) mold fixing platen.
4. Close the moving mold fixing platen in setup mode, move crane to match the clamping
movement, and ascertain mold height. Make sure the weight value shown on the crane
scales does not change when inserting the guide rods, otherwise raise or lower the
crane slightly.
5. Then build up and relieve the clamping force about 3 times, but without opening the
mold; simply relieve the clamping force. Building up and relieving the clamping force
allows for precise mutual alignment of the mold halves in the µm range. Make sure the
lifting force exerted by the crane exactly matches the dead weight of the mold. On tie-
barless machines, the display on the crane scales changes lightly due to frame defor-
91
mation and the accompanying lifting of the moving mold fixing platen from the guide rails
when the clamping force is built up. This effect is slightly greater on the ejector side mold
half than on the nozzle side.
6. With clamping force built up, tighten the ejector-side mold clamping screws. The for-
mula for minimum reach of screws is: Screw diameter x 1.5. The property class of the
screws should be 8.8 or 10.9 Harder screws can mean danger to the mold fixing thread
especially in the case of cast mold fixing platens. If using a high speed mold mounting
device build up clamping force before moving in the tensioning wedges.
7. Remove the crane and the rod, you can then open and close the mold, and start opera-
tions.
2.3.3 Factors that can affect the mold performance:
1 2 3 4
Different temperatures High operating Unparallel insulat- Eccentrically
of mold halves temperature ing platens arranged cavities
[1] Different temperatures of the two mold halves lead to different heat expansion, and thus
to different dimensions. This can cause more wear and tear, and misalignment of the
injection molded parts at the parting line.
[2] In the case of high mold temperatures, the non-centered mold half can be caused to
become uncentered during the warm-up phase. This is caused by heat expansion,
especially in case of asymmetric alignment of fixing points. This would result in coaxial
displacement of the two mold halves. In this case, it is necessary to attach the non-cen-

tered half with the crane again after heating up and to lift it as precisely as possible.
Then loosen the clamping screws for this half, and repeat the mounting procedure start-
ing at the step of building up and releasing the clamping force 3 times.
[3] Ensure true parallelism and constant wall thickness of any insulating platens used.
Deviations of >0.05 mm (>0.002 in) cause uneven distribution of pressure in the mold,
and can lead to overmolding and formation of burrs on the injection molded parts. Insu-
lating platens are subject to wear and tear. Always check parallelism and wall thickness
- especially if problems occur.
[4] Eccentric alignment of cavities requires more clamping force. The further cavities in an
asymmetric layout are from the center, the more clamping force is required to prevent
overmolding. Thus, when designing the mold, attempt to arrange cavities symmetrically
and close to the center.
93
2.4 Checking the coaxiality of the two mold halves
The coaxiality of the two mold halves is fairly easy to check using the following method. For
this purpose, you need to attach 3 magnetic holders with dial gauges to the outside of the mold
half with the centering bore (not the centering pin).
Procedure:
1. Close the mounted mold halves to a point where the centering pin is about to enter the
centering bore; do not allow the two to touch. Measure the vertical parallelism of the
platens operator side. The distance of the measuring points must be approximately the
distance from the end of the guide pin to the center of the (front) guide shoe (length a).
Note the parallelism values you measured.
2. Attach one magnetic holder directly above each of the two top guide bores To measure
the lateral displacement, attach a magnetic holder to the side of the top guide bore. The
following figures assume that the bores are in the ejector side mold half. If the bores are
on the nozzle side, you must also attach magnetic holders nozzle side. Then align the
dial gages with the top of the pin which is close to being inserted, and set the display to
zero.
Detailed drawing:
Guide pins not yet
inserted
3. Close the mold in set-up mode to a point where the guide pins are inserted into the
guide holes Make sure the feelers on the dial gages do not rest in a lubrication groove
on the guide pins. Now read off the dial gage. Detract the parallelism value from the

value you read off the two top dial gages, or add the value, depending on the platen par-
allelism direction (narrower or wider at the top).
Detailed drawing:
Guide pins inserted
Example:
The top gages show a value of +0.1 mm (+0.004 in) after entering the hole. The sensor is
’pressed in’, which means that the pins are being lifted, which in turn means that the mold half
with the bores (the ejector side in this case) is too high. If platen parallelism was 0.03 mm
(0.0012 in) higher at the top than at the bottom, you would need to subtract the 0.03 mm
(0.0012 in) from the insertion value of 0.1 mm (0.004 in) that you measured. This would result
in a vertical displacement of 0.07 mm (0.0025 in) caused by mounting. A value of less than
0.05 mm (0.002 in) would be okay; wear and tear to the tie-bars can occur for displacements
of 0.1 mm (0.004 in) or more. On large-capacity machines the displacement value can be far
higher without causing any problems.
95
2.5 Influence of the injection moulding machine on mold closing be-

havior
Different clamping mechanisms of injection molding machines can have a different influence
on the closing behavior of the mold. Among others, the following items are important:
Good platen parallelism of the machine is important for clean, wear-free closing of the
mold. Upon clamping force build-up the mold halves align on the mold parting surface,
with good platen parallelism tilting is less than with poor platen parallelism.
The rigidity of the frame has an effect on the straightness of the guides and thus on the
straightness of the closing movement. Under the load of a heavy moving mold half a soft
frame will be more severely deformed than a very rigid frame.
The accuracy of the concentricity of the center holes in the mold fixing platens plays an
important role in centering on both sides of the mold.
A look at different clamping mechanisms
ENGEL tie bar-less machine
The platen parallelism and concentricity of the center holes of an ENGEL tie bar-less machine
are adjustable and are optimally set on each machine. The frame is able to withstand the entire
clamping force. The load from the weight of the movable mold half and resulting frame defor-
mation is negligibly small compared to the clamping force. During the mold closing procedure
the frame is therefore hardly deformed; platen parallelism, concentricity and guidance accu-
racy are assured until the two mold halves come together.
ENGEL toggle lever machine
Platen parallelism and concentricity of the center holes are also adjustable on an ENGEL tog-
gle level machine machine via the adjustable support of the moving mold fixing platen. The
machine frame has a rigid welded construction. The double support on the accurate guide rail
makes the moving mold fixing platen extremely precise and tilt-free and frame bending is min-
imized.

ENGEL DUO machine
ENGEL large-scale machines are of 2-platen design and are known as

DUO machines. Platen parallelism and concentricity of the center holes are also adjustable on
this machine type via the adjustable support of the moving mold fixing platen. The machine
frame is supported on a large number of extremely stable machine shoes. Particularly long
support on the rigid guide rail ensures the precise and tilt-free movement of the moving mold
fixing platen.
Note!
Independently of the machine type used, it is important to mount the two mold halves as con-
centrically as possible to one another.
97
3 Setting up the barrel

The following section describes fitting and removing the nozzle, barrel and screw.
Use only original ENGEL barrel, nozzles and spare parts.
CAUTION!
Danger of damage to equipment due to improper settings!

If the maximum permitted barrel operating temperature is exceeded
(+350 °C or 662 °F), the screw and barrel can distort.
If the temperature is exceeded, a written permission must be procured
from the manufacturing firm ENGEL.
Note!
Observe the following, before working on the nozzle, screw, and plasticizing barrel:
1. Heat barrel to operating temperature.

2. Clean the barrel with a suitable cleaning agent and purge.
3. Refer to drawing of barrel in chapter Spare Parts.
WARNING!


Example: Injection unit 3550 - 45050
1 2 3 4 5 6 7 8 9 10 11
12
[1] Nozzle with nozzle heater and thermocouple

[2] Flange with fastening screws
[3] Barrel with barrel heating elements
[4] Barrel ring nut
[5] Material hopper with sliding unit for discharging
[6] Material feed opening
[7] Barrel - nut
[8] Screw coupling safety gate
[9] Screw
[10] Divided locking ring with fastening screws
[11] Screw coupling
[12] Tipping clamping lever for stabilizing the injection unit
99
4 Changing a nozzle
For some molds you need to fit a special nozzle instead of the standard nozzle.
Disassembly:
1. Switch off the machine motor.
Ensure that all function movements are blocked!
2. Heat the barrel and nozzle up to operating temperature.
3. Then switch off nozzle heater.
4. Dismount nozzle heating element with thermocouple.
5. Use a ring spanner to screw out the nozzle.
Assembly:
1. Check that nozzle and flange are clean, and clean if not (thread, sealing surface).
2. To keep the nozzle loose for future disassembly, apply a temperature resistant lubricant
to nozzle thread.
Lubricant temperature resistant: equal to/greater than: 600 °C (1112 °F)
Lubricant type: Loctite Anti-Seize 8150
3. Screw in nozzle up to stop (do not tighten!).
4. Clean the nozzle surface before fitting the heating element.
5. Fit nozzle heating element with thermocouple.
6. Use a torque wrench to tighten the screws on the heating element, paying attention to
the tightening torque. (see the following overview)
7. Switch on the nozzle heating.
8. After the nozzle and barrel have reached operating temperature, tighten the nozzle
according to the specified tightening torque.
Note!
Tightening torques are only applicable to the nozzle!
Nozzle tightening torque
M 28 x 1,5 200 Nm (147.5 lbf ft)
M 45 x 3 500 Nm (368.8 lbf ft)
M 55 x 3 800 Nm (590 lbf ft)
M 98 x 6 1700 Nm (1253.8 lbf ft)
Note!
For ceramic heating elements the screws must be tightened as follows:
Maximum application temperature of the medium to be heated 450 °C (842 °F).

DIN compliant screws912 Pretensioning in

Minimum rigidity 8.8 cold state
M5 2 Nm (1.475 lbf ft)
M6 2 Nm (1.475 lbf ft)
M8 2 Nm (1.475 lbf ft)
Note!
For glow plug heating elements the screws must be tightened as follows:
Maximum application temperature of the medium to be heated = 350° C (662° F).
DIN compliant screws912 Pretensioning in

Minimum rigidity 8.8 cold state
M5 6 Nm (4.425 lbf ft)
M6 11 Nm (8.113 lbf ft)
M8 18 Nm (13.28 lbf ft)
5 Changing the barrel

For optimum adjustment of the shot volume or for cleaning (e.g. material change), you may
need to change or remove and refit the barrel.
WARNING!
Danger of crushing in the screw coupling area and barrel anchoring

points!
Do not reach into this area while functional motions are in progress.
1 2 3 4 5
[1] Locking mechanism for barrel
101
[2] Nut for barrel

[3] Screw
[4] Split ring with Allen screws
[5] Screw coupling
Disassembly
1. Heat the barrel and nozzle up to the operating temperature.
2. If you have not cleaned the barrel, clean the barrel:
Depending on the material processed, use appropriate cleaning material (following
manufacturer's instructions for cleaning material!)
Repeat functions Plasticize and Inject until only cleaning material exits the barrel.
Then purge.
3. Switch off screw rotation by setting decompression before plasticizing to the same size
as the shot volume.
CAUTION!
To avoid damage, set a slow speed for injection, decompression and nozzle movement.
4. Advance the nozzle as far as possible without building up pressure.
5. To uncouple the screw, use the plasticize pushbutton (decompression) to retract the
screw to halfway through the plasticizing stroke.
6. Remove cover over screw coupling and split ring.
7. Advance the screw as far as possible by pressing the Inject pushbutton.
8. Use the Plasticize (decompression) pushbutton to move the screw coupling away from
the screw.
10. Dismantle the material hopper.
11. Remove the fastening screws of the base plate.
Fixing screws
Material hopper
Fixing screws
Base plate
12. Remove barrel protection from barrel.

13. Use 2 eyebolts to attach barrel to suitable lifting gear.

14. Uncouple the injection unit by removing bolts and retract the pull rods.
Bolt
Pull rod
15. Push back the injection unit manually and lock it using the tipping clamping lever.
16. Dismantle the nozzle protection.
17. Switch off barrel heating.
18. Detach all cable connections from barrel to heating distribution box.
19. Switch off the cooling of the traverse and tie off the cooling water hoses on the cooling
ring.
20. If needed, use an assembly aid to manually push the barrel out of the screw coupling
area.
21. Undo barrel nut and unscrew approx. 20 mm (0.787 in).
22. Use lifting gear to pull barrel carefully away from injection unit.
Assembly:
Basically follows the same steps as for disassembly but in reverse order.
103
6 Changing a screw
Due to specific plasticizing requirements for certain materials it can be necessary to use a
screw with a different kind of geometry.
Disassembly:
1. Lay barrel in dismounted state in horizontal position (see Changing the Barrel).
2. For easier screw removal the barrel should be at operating temperature.
3. Loosen heating element at flange.
Nozzle heating element with thermocouple
Flange with nozzle and Allen screws
4. Remove flange and nozzle by loosening and removing the Allen screws.
5. Pull the screw out of the barrel nozzle side.
If needed, use a mounting aid to push the screw forwards.
6. Position the return flow shut-off device outside the barrel (area from thrust collar to
point).
Thrust collar
Locking ring
Peak
7. Mount the return flow shut-off device key on the tip and remove the return flow shut-off
device from the screw with suitable equipment.
Non-return valve key
8. Remove blocking ring and blocking sleeve.

9. After removal of the tip, remove the material in hot condition with suitable equipment.
10. Switch off the barrel heating and the control voltage.
Assembly:
Installation of the screw basically follows the same steps as for disassembly, but in reverse
order.

CAUTION!
Danger of damage!
Reattach the locking ring of the screw correctly.
The screw must not have an axial play.
Correctly mounted locking ring:
Correct
Screw
Lock ring
Incorrectly mounted locking ring:
Wrong
Screw
Lock ring
Basically follows the same steps as for disassembly but in reverse order.
When refitting the screw, additionally note the following:
1. Before fitting the flange, you must clean the Allen screws and threads on the flange.
2. Lubricate the thread and head support of the Allen screws with a temperature resistant
lubricant to facilitate disassembly in future.
Lubricant temperature resistant: equal to/greater than: 600 °C (1112 °F)
Lubricant type: Loctite Anti-Seize 8150
3. Use a torque wrench to tighten the Allen screws. To ensure that the flange lies flush
against the barrel surface, alternately tighten 2 diagonally opposed screws, and then at
90°).
4. Clean the nozzle surface before fitting the heating element.
5. Fit nozzle heating element with thermocouple.
6. Use a torque wrench to tighten the screws on the heating element, paying attention to
the tightening torque. (see Fitting the Nozzle)
7. Pay attention to tightening torque.
(See the following overview)
Note!
The following tightening torques are valid for the barrel flanges for a maximum processing
temperature of 350 °C (662 °F).
105
Allen screw 10.9 tightening torque
M8 25 Nm (18 lbf ft)
M 10 48 Nm (35 lbf ft)
M 12 83 Nm (61 lbf ft)
M 16 202 Nm (149 lbf ft)
M 20 395 Nm (291 lbf ft)
Allen screw 12.9 tightening torque
M8 29 Nm (21 lbf ft)
M 10 57 Nm (42 lbf ft)
M 12 97 Nm (72 lbf ft)
M 16 236 Nm (174 lbf ft)
M 20 462 Nm (341 lbf ft)
Note!
The following tightening torques are valid only for the barrel flanges with Allen screws
40CrMoV47 for a maximum processing temperature of 350 °C to 450 °C (662 °F to 842 °F).
Allen screw 10.9 Allen screw tightening torque

12.9 40CrMoV47
M8 19 Nm ( 14 lbf ft)
M 10 37 Nm ( 27 lbf ft)
M 12 65 Nm ( 48 lbf ft)
M 16 155 Nm (114 lbf ft)
M 20 300 Nm (221 lbf ft)

7 Clean barrel and screw

Depending on material type, the screw should have been thoroughly cleaned beforehand with
cleaning material. The remainder may then only be removed in a dismantled state using brass
chisels. After preliminary cleaning, the unit must be cleaned in a blasting machine with round
grain plastic granulate.
Attention!
Do not use screwdrivers, steel chisels or sand in the blasting machine to prevent the surface
from being scratched. This will result in damage to the surface and can seriously affect the ser-
vice life of the screw.
Prior to installing the screw, the barrel must be cleaned with a rust-free steel wire brush
wrapped in a cleaning cloth.
8 Setting up the nozzle stroke transducer

After replacing the barrel, the nozzle stroke transducer must be moved by the distance equal
to the length difference of the barrels.
Recalibrate the nozzle stroke transducer after moving it.
107
Basic representation of small and large barrels
1
2
5 4
1
2
3 4
[1] Short and long pull rod

[2] Short and long barrel
[3] Stroke carriage cylinder
[4] Unit beyond machine contour
[5] Mechanical travel
[6] Difference between short and long pull rod

WARNING!
Danger of crushing due to moving components!

Your body or parts thereof can be crushed.
Do not place your hand in the area of functional movements while the
machine motor is running.
Switch off the machine motor.
Move the nozzle stroke transducer after installing the pull rods:
2. Loosen the fixing brackets.
Nozzle stroke transducer
Mounting brackets
3. Move the nozzle stroke transducer to the rear by the difference between the short and
the long pull rod.
At the maximum nozzle stroke, the position transducer must not move over the nozzle
stroke transducer.
Position transducer
14
4. Tighten the mounting brackets.
5. Calibrating the nozzle stroke transducer.
Calibration is described in ’Technical manual machine’ in chapter ’Performing stroke
calibration’.
Move the nozzle stroke transducer after removing the pull rods:
Basically follows the same steps as for ’Installing the pull rods’but in reverse order.
109
Note!
During the calibration of the rear nozzle position, the front nozzle position is automatically cal-
culated.
When the mold has been removed, the front position can also be calibrated.
Monitoring:
If the automatically calculated zero point is beyond the stroke transducer range, a message
appears.
Nozzle stroke transducer mounted incorrectly
Cause The nozzle stroke transducer has been moved too far back during
barrel replacement.
Effect A value for the nozzle zero point calibration cannot be calculated.
Remedy Also displace nozzle stroke transducer in proportion to the length of

the newly mounted
Moving the barrel.
The maximum nozzle value needs to be recalibrated.

9 Nozzle stroke limitation

For open construction type injection units stroke delimiting in automatic mode means that the
nozzle can only be raised to an extent that avoids danger of crushing between barrel and
nozzle protection. With the exception of the working stroke, advancing movements occur at
reduced speed of max. (20 mm/s).
When extremely long nozzles are used, a reduction of the nozzle stroke setting may occur
after determining the contact point. The following message is then displayed:
Nozzle stroke limitation
Cause Nozzle stroke setting longer than permitted. Danger of crushing!
Effect Automatic reduction of nozzle stroke setting.
When a longer barrel is fitted, it may be necessary to use longer pull rods for the injection unit.
For some open construction injection unit type machines the nozzle contact point may be out-
side the safety limit. Message:
Contact point not within stroke limits
Effect The alarm lamp flashes and the movement stops. Contact point not
determined
Remedy Check nozzle position. Recalibrate only if using longer tie-rods, and
without injection mold.
When a shorter barrel is fitted, it may be necessary to use shorter tie-rods for the injection unit.
For some open construction injection unit type machines the nozzle contact point may be out-
side the calibrated zero point. Message:
Nozzle stroke transducer defective
Effect Movement stops
Remedy Check nozzle position. Recalibrate only if using shorter tie-rods, and
without injection mold.
Retraction of the nozzle, reverse movement of the screw or mold opening can be reduced due
to frame length, e.g. by installing a longer barrel.
Limitations, interlocks, monitorings:

1. Actual value check:
If the sum of current positions of the nozzle, screw and moving platen (incl. mold height)
with Combi M units exceeds the stroke limit of the nozzle (screw, mold) the nozzle will
retract, screw return or mold opening be blocked.
2. Set value check:
If the sum of set positions for nozzle stroke (incl. nozzle contact position), metering
stroke (incl. decompression) or mold height and opening stroke with Combi M units
111
exceeds the stroke limit of the nozzle (screw, mold) the nozzle will retract, screw return
or mold opening be blocked.
Nozzle stroke limitation x reached
Cause Nozzle has reached stroke limit (sum of current positions or set
strokes).
Effect Nozzle and screw retraction (plus mold opening in Combi-M units) is
blocked, alarm lamp
Remedy Set nozzle advance or nozzle stroke (or opening stroke) smaller.
3. A limit switch for nozzle stroke limiting (screw, mold) on the unit's frame prevents nozzle
retraction and mold opening in Combi M units.
This limit switch is a safety limit switch and should normally never be actuated; see 1
and 2.
Nozzle stroke limitation x (limit switch) reached
Cause Nozzle has reached stroke limit (limit switch), safety limit switch was
actuated.
Effect Nozzle and screw retraction (plus mold opening in Combi-M units) is
blocked, alarm lamp
Remedy Set nozzle advance or nozzle stroke (or opening stroke) smaller.
9.1 Calibrating the nozzle stroke

Ascertain the maximum possible nozzle stroke on calibration.
1
2
3
4
5
6
7
[1] Stroke limitation for nozzle, short barrel

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

WARNING!
Danger of crushing between barrel and safety gate, and between barrel
and barrel support!
During calibration make sure a mold is not mounted.
Procedure at the calibration:
Note!
Access level 11 (Customer Service) is required for calibration. Movements throughout the
whole nozzle stroke up to the mechanical limits of the hydraulic cylinder must be possible.
1. Set machine to manual mode, and close safety gates.

2. Enable calibration by switching from Manual to Input calibration.
3. Use the pushbutton to move to maximum stroke, note the actual value on the Nozzle
screen. After reaching maximum stroke (mechanical stop on hydraulic cylinder), hold
the pushbutton down until the maximum value has been recorded.
4. Use the pushbutton to move in the other direction to minimum stroke, note the actual
value on the Nozzle screen. After reaching minimum stroke (mechanical stop on
hydraulic cylinder), hold the pushbutton down until the minimum value (0) has been
recorded.
5. Then move back in the other direction. The actual value must match the stroke pre-
cisely.
6. Disable calibration by switching from Input calibration mode to Manual.
113

Maintenance
Maintenance
Regular and carefully performed maintenance of the machine based on the maintenance
schedule guarantees:
Safety of operating staff
Best possible availability and life-expectancy
Cost savings
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Perform a visual check of the following items daily, during commissioning and during servicing:
Good working order of safety devices.
Check media lines for tightness and signs of wear.
Check oil level in sight glass
Check for sufficient lubrication (e.g. layer of grease, or black stripes on guide rails,
unusual noises, mechanical damage).
Check the water level in the water separator on the compressed air maintenance unit.
Drain condensation water at approx. 10 mm ( 0.4 in )
If available, check lubricant reservoir to ensure sufficient level of lubricant.
Top up if needed. Make sure you use the correct lubricant.
Empty the leakage oil reservoir.
WARNING!
Danger of fatal injury due to electrical voltage, high pressure, and mov-
ing machine parts!
Maintenance and repair work on the plant may only be carried out by
persons who have been trained for these tasks on ENGEL machines.
controls.
Prior to maintenance and repair work, move all vertical movable compo-
nents down to the mechanical stop or support them mechanically.
Maintenance and repair work should not be started until the main switch
is switched off and secured against switching on!
Make sure that electric circuits are powerless before working on them!
Before working on the pneumatics system, use the hand lever to shut off the supply to
the maintenance unit, and ensure that the unit is pressureless!
Make sure hydraulic circuit is pressureless before working on it!
Discharge pressure accumulators!
Pay attention to cleanliness during all maintenance and repair work!
Observe general safety and accident prevention regulations!
115
Maintenance
Observe the instructions in the chapter Safety!
Use only original spare parts.
ENGEL is not liable in case of:

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

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

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

Maintenance
1 Maintenance intervals
The control unit shows a digital time scale and a green progress indicator for 4 critical mainte-
nance intervals. The last 10% before a maintenance interval has elapsed are shown in yellow,
the next 10% after the interval has elapsed in red.
Maintenance intervals
Info Panel
Hours of operation
+
Total hours of operation
Maintenance interval 1
Days until maintenance
Maximum hours of operation before main-
Maximum hours of operation before main-
Maximum hours before maintenance re-
Hours of operation are only counted while the machine motor is switched on.
This maintenance must be carried out at the latest after 1440 operating hours, 500000 cycles,
or after a certain number of kilometers covered by a functional unit (clamping unit, ejector,
screw, nozzle).
The screen displays a percentage value for the current status and the remaining days until the
next maintenance interval (day counter).
Maintenance interval 2, 3
Working hours counter. Count only when machine motor is switched on.
Time counter. Counts the hours even when machine is switched off (8760 hours or 1 year)
A warning message signals that a maintenance period has expired:
Maintenance interval x
Cause Maintenance required.
Effect Message only.
Remedy Perform maintenance. Reset the counter by pressing the [R]button.

(access level 10 required).
117
Maintenance
Check the maintenance interval number to see which tasks are necessary.

Maintenance
1.1 Maintenance Schedule
The following work is required according to maintenance 1 2 3 4 Mainte-

interval nance
com-
pleted
Cleaning of machine X
[See Cleaning of machine on page 122.]
Visual check. X
Check media lines for tightness and signs of wear Check
cables and connectors for signs of damage.
Maintenance of the safety devices X

[See Maintenance of the safety devices on page 125.]
Clean the step safety (installed as of DUO 1000) X

- Remove sprue parts at the gap of the step plates.
(The maintenance of the step-on safety should be carried out
more often if required)
[See Step safety on page 134.]
Perform maintenance on auxiliary devices. X

[See Additional equipment on page 215.]
Automatic central oil lubrication X

[See Lubrication on page 150.]
Daily visual inspection of leakage oil catchment tank - empty X

as needed.
Grease guide rails. X

Lubricate guide rails on safety gate. X

Lubricate barrel support. X

Lubricate the swivel head locking cylinder thoroughly. X

Perform air filter maintenance on control cabinets. X

CAUTION: Do not operate without filter
[See Air filter maintenance on page 124.]
Check high-pressure, hydraulic hoses to ensure they are safe X

for operations
[See Hydraulics on page 162.]
119
Maintenance
The following work is required according to maintenance 1 2 3 4 Mainte-

interval nance
com-
pleted
Perform this task only on reaching Interval 2 for the first time. X
Take an oil sample and send it to the oil supplier for analysis.
Have the oil tested for water content and contamination. If
needed, filter or change the oil based on the supplier's recom-
mendation.
Check nozzle centering. X

[See Setting up for injection on page 75.]
Clean oil cooler X

Check sensors and machine accuracy X

[See Check machine - Ever-Q on page 121.]
Replacement of the filter element in the oil tank ventilation fil- X

ter.
Replace hydraulic oil (have the oil tested by your hydraulic oil X
vendor and replace oil filter if needed).
Check machine leveling X

[See Leveling the injection molding machine on page 51.]
Grease motor thoroughly if grease nipple is available. X

(with ESSO UNIREX N3.)
Grease rim bearing. (Option for unit 3550 and bigger) X

Oil piston rods of the injection cylinder always with hydraulic X

oil.
Grease the nozzle contact cylinder thoroughly if a grease nip- X

ple is available.
Grease the tiebar retraction device thoroughly (option) X


Maintenance
2 Check machine - Ever-Q

ENGEL has developed a computer-aided test and measuring system in order to check the pre-
cision of critical sensors and functions of the injection molding machine conveniently and reg-
ularly, and to perform calibration as needed.
Sensors are calibrated by performing comparative measurements with calibrated measuring
devices that comply with national standards. Critical technical characteristics of individual sub-
assemblies or sequences are tested under conditions similar to production conditions.
If measured values are outside of set tolerances, correcting measures are initialized. Mea-
sured data is visualized in tables and diagrams, and a test certificate is issued.
Customer benefit
Checking of sensors in compliance with VDA 6.1-13.3 requirements (QA 9000)
prevents mold sampling and production with incorrect data
is a prerequisite for the use of statistical methods for process optimization (e.g. Expert
Control)
guarantees the retraceability of the process data to national standards
facilitates the exchange of data between machines
helps to detect machine errors and wear at an early stage
represents an important decision making basis for required maintenance
EVER-Q Performance
For new machines EVER-Q can be performed by a trained ENGEL service engineer at the fac-
tory in addition to standard tests. ENGEL recommends a test interval of 1 to max. 3 years,
where subset of all EVER-Q tests is performed annually, or all tests are performed every 3
years.
For more detailed information on EVER-Q contact our main works or your local subsid-
iary's/dealer's service department.
121
Maintenance
3 Cleaning of machine
The best approach to ensuring long life and high precision operations is careful and regular
maintenance of your machine.
Make sure that safety equipment is kept clean!
This contributes considerably to keeping safety equipment working and thus provides best
possible safety for operating staff.
Pay special attention to the following instructions:

Use only soft cleaning rags for cleaning; never use wire wool or hard objects.
Clean the metal parts that are blank and painted only with the intended cleaning agent.
(For example: Tarco Super , Christ Lacke paint cleaner 968 .)
Clean all Plexiglas covers. Using warm water when applying a mild cleaning agent and
a soft cloth or sponge. (Never use concentrated disinfecting agents or solvents, such as:
Sagrotan, Lysoform, ethyl alcohol, acetone or other liquids containing alcohol under any
circumstances)
Clean all pictographs and warning/instruction labels. Make sure they are clearly legible!
Replace if needed.
Clean grease nipples to prevent dirt entering grease cavities during lubrication.
Clean guide rails, guide rods and piston rods carefully and always lubricate with oil after
doing so.
Clean the mounting surfaces of the mold fixing platens and whet with an oil stone if nec-
essary. The contact areas must be clean and free of grease to enable good friction
contact . If necessary, lubricate lightly to prevent corrosion (possibly with anti-corrosive
spray).
Keep motors free of dust and dirt deposits to avoid interfering with cooling.
The steel strip guides of the closing frame must be kept free of water.
After every mold change and leakage on the tool, remove water from the steel strip
guide of the moving mold fixing platen and carry out a lubrication cycle.
In order to keep the steel strip guides free of water we recommend the use of oil. [See
Central oil lubrication on page 158.]
3.1 Cleaning the control panel on the ENGEL control unit

CAUTION!
Danger of operator errors while cleaning the touch screen and controls!
Switch off the control voltage before starting cleaning.
Danger of damage to controls if non-approved cleaning agents are used.
Recommended cleaning agents:

Standard glass cleaner
Isopropanol (Alkohol)
Delothen (Plastic cleaner)
We recommend a soft cloth for cleaning.
Solvent resistance:
The control surface of the ENGEL control unit (C30/controls) is resistant towards the following
solvents:

Maintenance
Diesel, oil SAE, transmission oil

Äthanol
Antifreeze (Ethylenglykol)
Exception: Sodium hydroxide - causes slight, white coloring.
123
Maintenance
3.2 Air filter maintenance

The filter cartridge replacement interval must be determined individually based on dust con-
tamination levels and operating hours. A contaminated filter cartridge will cause the tempera-
ture in the switch cabinet to increase!
WARNING!
Danger of fatal injury due to electrical voltage in the switch cabinet!

Do not open the switch cabinet to replace or clean the air filter.
Procedure:
1. Switch off the main switch to shut down the fans.
2. Remove grating with filter mat by lifting.
3. Remove the filter mat from the grating.
4. Clean filter cartridge by blowing out with compressed air, or replace.
5. Insert the dust free filter mats into the lamellae grating.
6. Place grating with filter mat in the switch cabinet.
CAUTION!
Danger of contamination!
Never run the machine without an air filter!

Maintenance
4 Maintenance of the safety devices

Check all machine safety devices whenever you perform maintenance tasks.
Operating instructions [See Safety equipment functions on page 24.]
4.1 EMERGENCY STOP buttons

When EMERGENCY STOP is actuated, all motors of the machine must be switched off.
The position of the EMERGENCY STOP buttons depends on machine type:

on the injection molding machine operating panel
on the rear side of the injection molding machine
on the robot manual control unit
on the protection door in the safety guarding
within the safety guarding
Check all EMERGENCY STOP buttons in sequence as follows.
Procedure:
1. Close all safety gates
2. Switch on the motors
3. Actuate EMERGENCY STOP button
All movements and motors must stop immediately!
The alarm lamp must flash and EMERGENCY STOP must appear on the screen.
4. Release the EMERGENCY-OFF key by turning it to the right

5. Activate the Program Interruption switch to acknowledge the alarm
125
Maintenance
4.2 Moving safety gates

Carry out the following tests for all moving safety gates and protection doors:
Visual check for wear and damage.
Check fastenings, guides (for smooth running), stops and locking mechanisms by open-
ing and closing the safety gate.
Check the switching function of the safety and/or monitoring elements (e.g. limit
switches, valves, screen flags) by opening and closing the safety gate and/or protection
door.
Check whether all dangerous movements stop by opening the safety gate and/or pro-
tection door.
CAUTION!
Danger of damage from injection mold!

Dismount the injection mold if needed.
Retract nozzle, heat material barrel to correct temperature, and purge.
Set low speed (10%) for movements before doing so.
Procedure:
2. Switch on motor
3. Actuate the applicable machine movement and open the safety gate during the move-
ment.
The machine movement must stop immediately!
Message Safety gate x open
4. Close safety gate again
Note!
When opened, some safety gates trigger an EMERGENCY STOP. Check as per EMER-
GENCY STOP buttons.

Maintenance
Switching functions
Display of signals for checking the switching functions.
Example: Screen flags clamping unit safety gate closed
safety gate
Info Panel
+ Clamping unit safety gate

1 2 3
closed
open
Error
[1] Limit switch safety gate closed actuated (Signal 1)

[2] Limit switch safety gate open not actuated (signal 0)
[3] Safety limit switch for hydraulic safety valve not actuated (signal 0)
Example: Screen flags clamping unit safety gate open
safety gate
Info Panel
+ Clamping unit safety gate

1 2 3
closed
open
Error
[1] Limit switch safety gate closed (signal 0)

[2] Limit switch safety gate open (signal 1)
[3] Safety limit switch for hydraulic safety valve actuated (signal 1)
If the limit switches on the safety gate do not switch correctly, an error icon appears in the
Errors line for the flags in question, and an alarm:
Clamping unit safety gate x defective
Cause The two limit switches (1 and 2) on the safety gate are actuated or
deactivated simultaneously.
Effect Alarm lamp, motor stop.
Remedy Check for correct switching sequence of limit switches by opening

and closing the safety gate.
127
Maintenance
Clamping unit safety gate x (closing safety) defective
Cause The two limit switches (1 and 3) on the safety gate are actuated or
deactivated simultaneously.
Remedy Check for correct switching sequence of limit switches by opening

and closing the safety gate.
Note!
The functions and alarms also apply to a light beam guard.
Example: When the light beam guard is interrupted the control unit displays ’Clamping unit
safety gate open’.
Hydraulic closing safety
When the safety gate is opened, the hydraulic safety valve closes and interrupts the hydraulic
link to the clamping cylinder. The valve switching status is monitored by a limit switch.
If the closing safety does not switch correctly, an alarm icon appears in the Errors line for
the flags and alarms in question:
Hydraulic closing safety

1 2 3
Valve open
Valve closed
+ Error
[1] Hydraulic safety valve open (signal 1)

[2] Hydraulic safety valve closed (signal 0)
[3] Safety valve actuated (closing movement released hydraulically)
If the valve does not switch correctly, an alarm message is displayed:
Hydraulic closing safety defective
Cause The valve did not switch correctly within a second when the safety
gate was opened or closed.
Remedy Check perfect switching sequence of limit switch and safety valve by
opening and closing the safety gate.
For large-scale machines with cartridge and pilot valve:

Maintenance
Hydraulic closing safety cartridge defective
Cause The cartridge (globe valve) of the hydraulic closing safety has not
closed within one second during opening of the safety gate.
Remedy Check the cartridge of the hydraulic closing safety.

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

Nozzle safety gate
closed
open
+ Error
The following alarm is displayed if the limit switches do not switch correctly:
Nozzle safety gate defective
Cause The two safety gate signals are simultaneously ’’1’’ or simultaneously
’’0’’.
Remedy Check for perfect switching sequence of signals by opening and clos-
ing the nozzle safety gate.
129
Maintenance
4.3 Safety guarding

Carry out the following tests for all moving safety gates and protection doors:
Visual check for wear and damage.
Check fastenings, guides (for smooth running), stops and locking mechanisms by open-
ing and closing the safety gate or protection door.
Check the switching function of the safety and/or monitoring elements (e.g. limit
switches, valves, screen flags) by opening and closing the safety gate and/or protection
door.
By opening a safety gate and/or protection door check whether all dangerous move-
ments are blocked.
Example: safety guarding with protection door

3
2
1
0 5
7
6
IT
QU
30
XH
[1] Limit switch (BE 2.x) actuated while protection door is open
[2] Limit switch (BE 1.x) actuated while protection door is closed
[3] Limit switch (BE 7.x) is actuated while the protection door is open (electro-hydraulic
closing safety)
[4] EMERGENCY STOP button outside
[5] Access request key with lamp
[6] Acknowledgement key with key-operated switch
[7] EMERGENCY STOP button inside

Maintenance
CAUTION!
Danger of collision damage!

When checking, make sure that no collisions occur between the robot,
injection molding machine and the peripheral units. Observe the take-
over head and mold safety.
Set low speed (e.g. 10%) for the movements before.
Check all protection doors individually as follows:
2. Open - close protection door and acknowledge (within 5 seconds) using the key-oper-
ated switch. Protection doors lock mechanically.
3. Switch on the motors.
4. To open the mechanically locked protection door, actuate the access request key (key
flashes). The injection molding machine stops at the end of the cycle.
5. The access request key lighting up indicates that the protection door has been unlocked
and enabled for opening.
6. Actuate the applicable machine movement and open the protection door during the
movement.
The machine movement must stop immediately!
The message Safety gate x open is displayed
To check the switching function on the safety gate in question, the signals are listed on the
’Safety gate’ screen.
Clamping unit safety gate 2

The safety guarding with protection door is connected to the injection molding machine via a
plug in place of the rear safety gate of the clamping unit.
The limit switches in the protection door thus assume the function of the rear safety gate limit
switches on the clamping unit.
safety gate
Info Panel
+
closed
open
Error
closed / open
Signals from limit switches of the protection doors to the injection molding machine if the
safety guarding with protection door is connected to the injection molding machine.
If the rear safety gate on the clamping unit is connected, the signals are issued by the
injection molding machine's limit switches.
Error
This line shows error symbols if the limit switches are not switching properly.
Clamp unit safety gate acknowledgement 2
131
Maintenance
acknowledged
+ Not acknowledged
completely open
Robot safety gate 2
Safety gate 2 acknowledge button
acknowledged / not acknowledged
The acknowledged and not acknowledged signals are signals from the injection
molding machine whose signal state changes when the protection door is acknowl-
edged or opened.
Guarding active
This flag indicates that the safety guarding with protection door is connected to the
injection molding machine.
completely open
This flag indicates that the rear safety gate on the clamping unit is completely open
when the machine is operational.
When the acknowledgement key is pressed, two contactors are actuated simultaneously The
control unit monitors the contactors for correct position to one another.
Acknowledgement contactor x defective
Cause Monitoring inputs of the acknowledgement contactors were simulta-

neously active/inactive for more than 1 second.
Effect Motor stop, heating reduced, alarm lamp
Remedy Acknowledgement contactors and their counterequal switching posi-

tion must be checked.
The error state remains following control voltage switch-off until error
acknowledgement.

Maintenance
4.4 Automatic safety gate

Carry out the following tests for automatic safety gates:
Visual check for contamination and damage.
By opening the safety gate in manual mode check that all potentially dangerous move-
ments are stopped.
Procedure [See Moving safety gates on page 126.]
Check correct functioning of the safety strip

+
Safety gate 1 brake opening
final position Braking limit switch Safety strip
closed
open
controller release
Direction Open Close
Safety edges are fitted to the safety gate to protect persons. When actuated the safety gate
movement stops and the following message is displayed:
Safety gate safety strip opening active
Effect The safety gate cannot be opened automatically. After a short stand-
still time the safety gate slowly moves in the opposite direction.
Remedy Check safety strip
4.5 Maintenance safety gate

1 2
[1] The automatic safety gate (mold area) can only be opened / closed when the safety
gate behind the moving mold fixing platen has been closed.
[2] Additional limit switch Maintenance safety gate 1 closed
133
Maintenance
Clamping unit maintenance safety gate x open
Cause The safety gate behind the moving mold fixing platen is open.
Effect Clamping unit side movements are blocked, also opening and closing
the automatic safety gate
4.6 Step safety

Step-on plates in the clamping unit area prevent machine movements when a person is within
the machine's safety gates.
WARNING!
Danger of fatal injury if safety equipment is not cleaned!

Keep safety floor plates (plate elements)clean at all times (e.g.: remove
sprue, injection molded parts, etc.). Parts jammed in the gap between
the steps can impact the functionality of the steps.
Clearing must only be carried out when the machine is switched-off.
Clean the step-on plates at each routine maintenance.
Example: DUO 1000 with 5 zones, zone 2 defective and color-marked

Step safety
Step-on safety 1 deactuated

Performance test:
The step safety test is started when the control voltage is switched on and after 7 days in man-
ual mode have elapsed. Condition: no emergency stop and safety cover on the clamping unit
closed.
The pneumatic cylinder actuates the step safety (Step safety test signal) and the control unit
checks the returned limit switch signal (Step safety 1 actuated).
Alternatively the test can be carried out by entering the step safety.

Maintenance
At the start of the test all limit switches are marked as defective with red question marks.
Thereafter each limit switch must have switched once.
If the test fails, the following message appears:
Test step safety!
Cause: A test of the step safety has started and is not completed!
Effect: All machine movements and automatic mode blocked;

All movements except for mold closing supported only in setup mode.
Remedy: Automatically with existing compressed air of the pneumatic cylin-

ders.
Manually by entering all areas of the step safety.

You can also start the step safety test manually, but only in manual mode, the motors must be
switched off.
Trittsicherung absenken bei öffnen Schutzverdeckung

The activated functions facilitate walking on step-on plates.
The step-on plates are pulled downwards when a safety gate is opened by pneumatic cylin-
ders.
However, this only functions when the step safety test was error-free.
This function is normally enabled, but can be switched off on the Var monitor.
In the event of an emergency stop and control voltage is switched off, the step-on plates will
remain up.
If the functional test succeeds, motor start is enabled.
4.7 Safety gate on clamping unit side

Fixed safety gate - protection doors as of DUO 800.
WARNING!

injection!
The safety gate may only be closed if the hazard zone is clear of staff
and foreign bodies.
To allow maintenance or repair work, a protection door is mounted on the face end of the
clamping unit or on the front side of the fixed safety gate. Alternatively both protection doors
are installed.
The protection door is secured by limit switches which stop all machine movements in this area
when the door is open. An EMERGENCY STOP button is installed on the inside close to the
door.
135
Maintenance
Example with protection doors on the face side and front of the fixed safety gate
[1] 3. Protection door

[2] 4. Protection door (option)
[3] EMERGENCY STOP button on inside
For convenient checking of switching function of safety gates, you can access a screen to dis-
play the signals. When the safety gate is closed all screen flags in the line must be active.
Example: Screen flags of safety gate of clamping unit 3 closed

1 1
closed
open
+
Error
[1] Limit switch signals of safety gate
When opening the safety gate in the manual mode, appears the message:
Clamping unit safety gate x open
Effect All machine movements stop.
Remedy Close the protection door.
When opening the safety gate in the automatic mode, appears the message:
Clamping unit safety gate x interrupts cycle
Effect The automatic cycle and all movements stop, a delayed motor stop is
initiated, a delayed switchover to standby heat is initiated and the
alarm lamp flashes. The delayed switch over time is 2 minutes.
Remedy Close the protection door, move the functional units to start position
and restart the cycle.

Maintenance
If a protection door is on the front of the fixed safety gate, electrical opening/closing of the mov-
ing safety gate on the operator side is blocked.
The protection doors are monitored in the same way as the safety gates, for simultaneous
actuation/non-actuation.
Clamping unit safety gate x defective
Cause Limit switches activated/deactivated simultaneously for more than 1

second.
Effect Cycle interruption, motor standstill, heating reduced, alarm lamp
Remedy Check proper switch sequence by opening and closing protection

door. Check mounting and setting of limit switches.
For variant with acknowledgement the following conditions must be observed.
WARNING!

injection!
The person inside the safeguard must always possess the key from the
key-operated acknowledgement switch in order to prevent accidental
acknowledgement of safeguards, which would cause the machine to
restart.
Do not acknowledge the safety guard until the danger area is clear of
personnel and foreign bodies.
Acknowledgement with the key button is required after quitting the safety zone and closing the
safety gate.
Example: Screen flags of safety gate acknowledgement of clamping unit 3 - confirmed

1 1 Acknowledgement
2 key
acknowledged
+ Not acknowledged
[1] Safety gate signals

[2] Acknowledgement key pressed
An acknowledgement must occur after switching on the control voltage The following message
is displayed until you acknowledge the protection door:
137
Maintenance
Acknowledge safety gate x
Effect All machine movements are blocked.
The acknowledgement must occur within 5 seconds of, but not within 0.05 seconds after clos-
ing the protection door.
You are not permitted to press the acknowledgement key for too long (maximum of 10 sec-
onds). If these conditions are not fulfilled, the following message appears:
Safety guarding x acknowledgement time exceeded
Cause Protection door not acknowledged
Effect Motor stop, alarm lamp
When the acknowledgement key is pressed, two contactors are actuated simultaneously The
control unit monitors the contactors for correct position to one another.
Acknowledgement contactor x defective
Cause Monitoring inputs of the acknowledgement contactors were simulta-

neously active/inactive for more than 1 second.
Remedy Acknowledgement contactors and their counterequal switching posi-

tion must be checked.
The error state remains following control voltage switch-off until error
acknowledgement.
4.8 Safeguarding closing mechanism
Note!
For machines with a clearance between the tie bars of 1200 mm or more, the „Safeguarding
clamping mechanism” limit switch is attached to the moving mold fixing platen.
For machines that are to be exported to North America, the „Safeguarding clamping mecha-
nism” limit switch is attached by default.
Note!
In standard all movements on the clamping unit are blocked with open safety gate, even when
the machine is equipped with limit switch „Safeguarding clamping mechanism area”, entering
behind safety and gripping behind safety.

Maintenance
Limit switch Sliding safety gate
Function:
The limit switch makes a „Safety gate opening” in the „Automatic mode” only possible
up to the platen area of the moving mold fixing platen.
Therefore this safety device protects against a manipulation in the danger area of the
mold clamping mechanism and of the ejector during ”Mold opening”.
Functional check:
In the normal state the limit switch is deactuated.
When the safety gate is pushed over the platen area of the moving mold fixing platen
(safety gate operation switched over to „MANUAL”), the limit switch is actuated. An
„Emergency stop” function occurs.
The pump motor is switched off.
The motor can only be started again after closing the safety gate and acknowledgement
with PU key.
4.9 Locking of manual safety gate (from DUO 800)

For a clearance between the tie bars of 1200 mm or more, the safety gate must be locked.
The locking safety gate prevents an unwanted closing of the safety gate.
The safety gate locking prevents unintentional closing or opening of a manual safety gate.
Press in the black button so that you can close or open the safety gate.
Display of manual locking unit, view from mold area.

Represented in locked state.
Complete closing of safety gate is blocked.
139
Maintenance
1 2
[1] Manual locking unit,

Spring-loaded locking
[2] 1 Limit switch integrated into locking unit.
[3] safety gate.
Display on screen page Safety gate:
Locking safety gate

A192:DI15
unlocked
+ locked
Open-close safety gate sequence:

1. Unlock safety gate locking Press ball knob.
2. At the same time, close or open the safety gate.
Limit switch monitoring:

The control unit monitors the limit switch for locking moved in and safety gate closed for
antivalence.
The signal state changes within a fixed time of approx. 5 seconds. This can be con-
figured via a machine parameter in the variables monitor.

Maintenance
If a malfunction occurs, the motor stops, the alarm lamp lights up and a switchover
to manual mode occurs. The motor can be started again only after the error has been
eliminated!
Monitoring programs of this kind are protected against program loss for reasons of
safety.
Locking safety gate defective
Cause: If the limit switch for locking moved in and safety gate closed does not
change state antivalent within the monitoring time, this error is set
(e.g. simultaneous actuation of both limit switches).
Effect: Motor stop
Remedy: Check locking and/or limit switches.
Error acknowledgement:
In a case of error the error state is stored.
An error-free movement cycle of the locking and safety gate must occur to rectify the
error,
i.e. the signal states must change correspondingly within a fixed time.
If a malfunction occurs, it is not reset by switching the control voltage off/on.
4.10 Locking of electric safety gate (from DUO 800)

For a clearance between the tie bars of 1200 mm or more, the safety gate must be locked.
The locking safety gate prevents an unwanted closing of the safety gate.
The safety gate must be unlocked with the pushbutton.
141
Maintenance
Top view of electromagnetic locking safety gate.

Shown in locked state Closing of safety gate is completely blocked.
1
2
[1] Electromagnetic locking unit.

[2] 2 Limit switch integrated into the electromagnetic locking safety gate.
[3] safety gate.
Display on screen page Safety gate:
Locking safety gate

A192:DI15 A192:DI12 A42:D025
locked
+ unlocked
Sequence close safety gate:

1. Move out (unlock) safety gate locking with pushbutton „Locking move out safety gate”.
When the pushbutton is briefly pressed, locking remains activated for approx. 3 s.
2. If the „Close safety gate„ pushbutton is pressed during this time, locking remains acti-
vated until the safety gate has been closed.
Monitoring:
To be able to close the safety gate, the safety gate lock must be moved out (unlocked),
i.e. limit switch for locking moved out actuated (+24V),
Otherwise the safety gate will be prevented from closing;

Maintenance
Locking safety gate not moved out
Cause: From a distance between tiebars of 1200mm the safety gate must be
closed in two-hand control. If the locking provided for this purpose is
not moved out (unlocked), this error is set.
Effect: The safety gate cannot be closed automatically
Remedy: Locking move out safety gate with pushbutton „Locking move out
safety gate”.
Check locking, actuation and/or limit switch.
Limit switch monitoring:

Only with open safety gate!
The control unit monitors the limit switches for locking moved out and moved in for non-
equivalence operation.
Change of the signal state within a fixed time.
If a malfunction occurs, the motor stops, the alarm lamp lights up and a switchover
to manual mode occurs. The motor can be started again only after the error has been
eliminated!
Monitoring programs of this kind are protected against program loss for reasons of
safety.
Locking safety gate defective
Cause: When the limit switches for locking moved out and moved in do not
change their state in non-equivalence operation within the monitoring
time, this error is set (e.g. simultaneous actuation of the two end posi-
tions switches).
Effect: No mold movement
Remedy: Check locking and/or limit switches.
In a case of error the error state is stored.
For the error elimination an error-free movement cycle of the locking safety gate must
occur,
i.e. the signal states must change correspondingly within a fixed time.
If a malfunction occurs, it is not reset by switching the control voltage off/on.
Electric safety gate on the non-operator side:
143
Maintenance
Note!
The functionality of the locking safety gate on the operator opposite side is executed identical
to that on the operator side.
4.11 Mechanical closing safety

The mechanical closing safety prevents unwanted closing of the clamping unit. It acts in addi-
tion to the electrical and software-based interruption of the mold closing movement and mold
height adjustment.
Function:
On each of the two high speed clamping cylinders a simply acting closing safety is mounted.
When the safety gate on the clamping unit is open or during an EMERGENCY STOP, the clos-
ing safety closes spring-actuated and prevents the clamping unit from closing.
Conditions for unlocking the mechanical closing safety:

All safety gates closed
Error-free limit switches of the safety gates
Pilot valve of the hydraulic closing safety OK
Step safety not actuated
Motors run on delta
Mechanical closing safety

move out
locked
+
Error
Note!
If a closing safety does not unlock, the clamping unit must be opened approx. 20 mm in set-
up mode with the pushbutton ’Mold opening’ and then attempt mold closing again.

Maintenance
In the error case, the following message appears:
Mechanical closing safety defective
Cause a) The limit switches for the mechanical closing safety have and/or
have not been actuated at the same time longer than 1 second
or
b) The limit switch for the mechanical closing safety moved in and the
limit switch for safety gate closed have been unequal longer than 1
second.
Effect Motor stop, alarm lamp
Remedy Carry out an error-free switching process with the clamping side
safety gate
Mold opening when safety gate is open (option)
Function:
As the mechanical closing safety is moved in in the standard case with open safety gate, this
circuit must be modified for the option ’Mold opening with open safety gate’ so that the
mechanical closing safety is moved out via an additional output.
In machines designed to SPI safety regulations, the SPI safety key switch must also be actu-
ated.
As a result under the following conditions the mechanical closing safety is moved out via an
additional output:
Machine is in ’Semiautomatic mode’
Clamping unit is not opened for the ’Opening stroke’
’SPI key-operated switch’ is active,
(at machine execution according to SPI safety regulations)
Mechanical closing safety with open safety gate

move out with open safety gate
Error
+
For this purpose additional monitorings are provided.

1. Algebraic sign check of the mould stroke:
As with open safety gate during the mold opening movement the mechanical closing
safety is moved out, it is checked whether the mold actual value also really rises.
If this is not the case, the drive motor is switched off and the mechanical closing safety
is moved in again, and the error ’Mold movement wrong’ is displayed.
145
Maintenance
2. Bridging of the hardware interruption of the valve for moving out mechanical closing
safety during the mold opening movement with open safety gate:
Via a separate output of the control unit two contactors are actuated, with which during
the mold opening movement, with open safety gate, the mechanical closing safety is
held in the moved-out state also in terms of hardware.
The output is set at start mold opening, even when the safety gate is still closed.
The contactors are monitored for antivalence in the control unit towards each other, and
towards the output.
In the error case, the following error messages appear:
Mold movement wrong
Cause The mold stroke actual value has not increased when mold opening
with open safety gate and moved out mechanical closing safety, it
has decreased.
Effect Mechanical closing safety moves in,

Motor stop, alarm lamp
Remedy Check hydraulics and mold stroke transducer, carry out an error-free
switching process with the clamping side safety gate
Mechanical closing safety contacts
Cause The inputs for the contactor monitoring for the mechanical closing
safety, at option mold opening with open safety gate, are not in the
correct position to each other and/or towards the actuation within a
fixed time.
Effect Mechanical closing safety moves in,

Motor stop, alarm lamp
Remedy Check contactors and contacts, carry out an error-free switching pro-
cess with the clamping side safety gate

Maintenance
Hint to monitoring circuits:

The monitoring function safety gate position regarding the position of the mechanical closing
safety is disabled during ’Mold opening with open safety gate’.
When an error appears in criterion 1. or 2., the drive motor is switched off, the mechanical clos-
ing safety is brought in the blocking position, the mentioned monitoring function is activated
again and an error message is output.
In a case of error the error state is noted.
For error rectification, an error-free movement cycle of the mechanical closing safety must be
implemented (mold standstill / mold opening), i.e. the signal states must change within the
fixed time.
If an error occurs, it is not reset by switching the control voltage or main switch off/on.
For check for correct state motor start as well as mould opening with set-up speed is required.
Automatic start is prevented.
Mode of operation Electric safety gate:
Note!
Only with electrically driven moving safety gate clamping unit!
As the safety gate can open already before or during the mold opening and the safety gate
could move on the EMERGENCY STOP limit switch ’Safeguarding closing mechanism area’
on the moving mold fixing platen, an additional limit switch is mounted shortly in front of limit
switch ’Safeguarding closing mechanism area’ , which stops the opening of the safety gate.
This limit switch is switched electrically in parallel to limit switch ’Safety gate 1 entirely open’ .
The safety gate must be operated here electrically, limit switch-controlled.
Emergency stop limit switch ’Safeguarding mold clamping mechanism area’ must be mounted.
147
Maintenance
4.11.1 Add-on for mechanical closing safety with electrical safety gate
Note!
Only with electrically driven moving safety gate clamping unit!
As the safety gate can open already before or during the mold opening and the safety gate
could move on the EMERGENCY STOP limit switch Safeguarding closing mechanism area
on the moving mold fixing platen, an additional limit switch is mounted shortly in front of limit
switch Safeguarding closing mechanism area , which stops the opening of the safety gate.
This limit switch is switched electrically in parallel to limit switch Safety gate 1 entirely open .
The safety gate must be operated here electrically, limit switch-controlled.
Emergency stop limit switch Safeguarding mold clamping mechanism area must be
mounted.
4.12 Safety limit switch for swiveling out injection unit

Swiveling out the injection unit makes it easier to set up the barrel for injection. A limit switch
locks all injection unit movements when the injection unit is swiveled out.
Functional check:
Press limit switch to ensure that all hazardous movements are stopped.
CAUTION!
Danger of damage from injection mold!

Dismount the injection mold if needed.
Retract nozzle, heat material barrel to correct temperature, and purge.
Set low speed (10%) for movements before doing so.
Procedure:
2. Switch on motor
3. Injection unit in operating position (swiveled in).
4. During a function movement on the injection unit,
for example: Advance injection unit , manually actuate the safety limit switch.
The functional movement Advance injection unit must stop and an error message
appears.

Maintenance
Nozzle swivelled out
Effect Cycle interruption.
Remedy Swivel in nozzle.
Note!
For machines with pressure accumulator, the safety limit switch for swiveling out the injection
unit is covered by the EMERGENCY STOP system
Functional check for machines with pressure accumulator

2. Switch on the motors
3. Open nozzle safety gate (not for injection unit with open construction type)
4. Actuate limit switch manually.
All motors must stop immediately!
The alarm lamp must flash.
An EMERGENCY STOP alarm message is displayed.
All machine movements must be blocked!
5. Activate the Program Interruption switch to acknowledge the alarm
Note!
The EMERGENCY STOP function is active in each mode of operation!
149
Maintenance
5 Lubrication
Lubrication is required of all moving parts and drives in which metallic elements interlock. Pre-
mature wear may otherwise occur, reducing the lifetime or even causing total failure.
Example: Clamping unit DUO 800 4000

Clamping unit side
1 2
[1] Joint head locking cylinder

[2] High speed clamping cylinder
[3] Automatic central oil lubrication (grease pump).
[4] Tie-bar retraction device (option).
Joint head locking cylinder
Lubrication point
Lubrication point
Lubrication frequency according to maintenance schedule (Maintenance interval 1)

The grease type specified in the lubrication table must be used
Grease the lubrication point until grease starts to escape.

Maintenance
Quick shot barrel
Lubrication point

Tie-bar retraction device (option)
Lubrication point

Daily visual check of automatic central oil lubrication
max level
min level
151
Maintenance
The oil level must be between the min/max levels!

The lubricating oil specified in the lubrication table must be used
Emptying catchment tank
Leakage oil catchment tank
Daily visual inspection of all four leakage oil catchment tanks.

Observe local waste disposal laws when disposing of oil.

Maintenance
Example: Injection unit side 16050-23050

Injection unit side
1 2 3
[1] Injection unit guide

[2] Material cylinder support
[3] Nozzle carriage cylinder
[4] Pump motor
Injection unit guide
Lubrication point

Required grease amount: approx. 1.4 cm³ (0.00037 gal) per lubrication point and greas-
ing routine
Note!
After the application of grease advance and withdraw twice (full stroke). Now apply grease a
second time.
153
Maintenance
Material cylinder support
Lubrication point
Material cylinder suppor
The grease type specified in the lubrication table must be used.

Lubrication frequency according to maintenance schedule. (Maintenance interval 1)
Required grease amount: approx. 2 cm³ (0.00053 gal) per lubrication point and greasing
routine
Nozzle carriage cylinder
Lubrication point
The grease type specified in the lubrication table must be used.

Lubrication frequency according to maintenance schedule. (Maintenance interval 4)
Required grease amount: approx. 1 cm³ (0.00026 gal) per lubrication point and greasing
routine
Pump motor
Lubrication point
Grease thoroughly if grease nipple is available. Only use ESSO UNIREX N3 ENGEL
Order No. 06715-0023.

Maintenance
Piston rod of injection cylinder
Piston rod
Oil piston rods of the injection cylinder always with hydraulic oil
155
Maintenance
5.1 Lubricant survey
Grease lubrication Hydraulic oils zinc- Non-zinc hydraulic

manual based oils
norm DIN 51825 KP2K-20 DIN 51524-2 DIN 51524-2

Lithium saponified ISO VG46 ISO VG46
OMV OMV HYD HLP 46 HYD HLP AL 46

LITHPLEX EP 2 OMV HYD HLP-SH46
ARALUB HLP 2 ARAL VITAM GX 46 ARAL VITAM GF 46
AGIP AGIP
GR MU EP 2 OSO 46
ENERGREASE ENERGOL HLP HM

LS EP 2 46
SPHEEROL HYSPIN AWS 46

EPL 2
GLISSANDO ASTRON HLP 46

EP 2
BEACON EP 2 NUTO H 46

Maintenance
Grease lubrication Hydraulic oils zinc- Non-zinc hydraulic

manual based oils
MOBILUX EP 2 DTE 25 DTE EXCEL 46
ALVANIA TELLUS 46 TELLUS S 46

EP GREASE 2 TELLUS S2 M 46 TELLUS S3 M 46
SUNAPLEX SUNVIS 846 WR

992 EP
MULTIFAK EP 2 RANDO
OIL HD C 46
-MULTIS EP 2 TOTAL AZOLLA ZS46 AZOLLA AF 46
Note!
A lubricant safety fact sheet is available from the manufacturing works on demand.
157
Maintenance
5.2 Central oil lubrication

Central oil lubrication is typically deployed for slide rails and lever joints. A central oil lubrica-
tion schematic is available in chapter Plans and Protocols.
Note!
The oil reservoir for the pump must contain sufficient circulating oil at all times!
Check the filling level regularly and top up as needed!
[1] Min. level

[2] Max. level
[3] Filler cap for lubricant
Central lubrication
Info Panel
+ Range 1:
Cycles Time
Set value times min
Actual value times min
Lubrication pressure 1 mini-
Lubrication pressure 1 maxi-
Start manual lubrication
Oil level/Pump
Lubricating oil level 1 OK
Cental lubrication pump
Range 1:
Set value
The preset Cycles or preset Time determine lubrication intervals.
Which ever of the set criteria applies first will trigger a lubrication cycle.
The flag next to Cycles or Time shows the criterion that triggered the last lubrication
process.

Maintenance
Actual value
This line shows the number of minutes and cycles that have occurred since the last
lubrication process.
Lubrication pressure 1 minimum
After completing the lubrication process the pressure must drop to 2 bar (30 psi) within
the monitoring time. If not, the following message appears:
Lubrication pressure not relieved
Cause Lubrication line blocked.

The max. pressure switch is actuated, or the min. pressure switch is
not actuated.
Effect Mold closing is blocked, the alarm lamp flashes, no new cycle start,
motors ramp off, heating ramped down.
Remedy Check lubrication points and lines.
Lubrication pressure 1 maximum

Within the lubrication process the lubrication pressure must reach the maximum of 20
bar (290 psi). If not, the following message appears:
Lubrication pressure not built up
Cause Leakages or air in the lubrication system, pump not running or not
pumping, pressure switch defective.
Effect Central lubrication pump stops, mold closing blocked, the alarm lamp
flashes, no new cycle start, motors ramp off, heating reduces
delayed.
Remedy Fix leakage. You may be able to vent air by manually starting the
lubrication system. Check pump and pressure switch.
Resetting Switch the program interruption key on and off. This starts a new
lubrication cycle. After completing lubrication, automatic acknowl-
edgement occurs.
Start manual lubrication

Switch for starting a lubrication process e.g. if the machine has not been used for a lon-
ger period of time, where possible before the first actuation of the clamping unit.
After 30 days standstill, the control unit automatically starts a triple lubrication process
for the clamping unit.
Oil level/Pump
Oil level 1 OK
The following message appears if the oil level is too low:
159
Maintenance
Lubrication oil level too low
Cause The lubrication oil level in the central lubrication reservoir is too low.
Effect In automatic mode: Only the alarm lamp will flash.

While lubrication is active: the alarm lamp flashes, central lubrication
pump stops, new cycle will not start, mold closing will not continue,
motors ramp off, heating ramps down.
Remedy Top up with oil.
Resetting Switch the program interruption key on and off. This starts a new
lubrication cycle. After completing lubrication, automatic acknowl-
edgement occurs.
Cental lubrication pump

The flag shows that the central lubrication pump is running.
Overview of lubricants:
Oil for
Central lubrication
norm DIN 51517 T3

CG 68
OMV ÖL G 68
ARAL
DEGANIT
B 68
AGIP
EXIDIA 68
BP
ENERGOLGHL 68 ISO
CASTROL-MAGNA BD 68
NOVAN CGLP 68

Maintenance
Oil for
Central lubrication
FEBIS K 68
MOBIL
VACTRA OIL Nr.2
TONNA T 68
SUNOCO WAY LUBRICANT 80
TEXACO WAY LUBRICANT 80
DROSERA MS 68
Note!
Danger of damage to equipment!
If you have a query concerning lubrication, please contact your local ENGEL subsidiary/dealer
or the ENGEL works.
Oil for
Central lubrication
HYDROKAPILLA P48
Note!
In order to keep the steel strip guides free of water, we recommend the use of oil (ENGEL
Order No. 04201-0017) for central lubrication [See Cleaning of machine on page 122.]
161
Maintenance
6 Hydraulics
Sight glass, hydraulic oil tank, low-pressure filter, oil cooler and pump of a standard
injection unit.
1 2
5 4 3
[1] Sight glass

[2] Hydraulic oil tank with filling cap
[3] Low-pressure filter with soiling indicator (red button)
[4] Oil cooler
[5] Pump for oil filtration
6.1 Hydraulic system
6.1.1 Pump
If a pump malfunction occurs, contact your local service engineer.
Some machines have tank shut-off valves to help remove the defective pump. If the tank shut-
off valve is not completely open, the following message appears:

Maintenance
Tank shut-off valve(s) closed
Cause Throttle valve in the pump suction line is not open.
Note!
After fitting a pump (e.g. after repairs or replacing a pump) you must fill the pump with clean
hydraulic oil (of the same quality as in the oil tank) via the leakage oil connector (line to oil
tank) up to the top of the leakage oil screw!
6.1.2 Hoses
Hoses are subject to natural aging. This restricts their working life.
The owner of the injection molding machine must ensure that hoses are replaced at regular
intervals, even if no safety-relevant damage to the hose is evident.
The period of use must not exceed a maximum of 6 years from manufacturing date of hose.
1 2 3
[1] Fitting
[2] Insert
[3] Outer layer
WARNING!

All hoses on the injection molding machine must be checked at least
quarterly to ensure they are safe for use.
This test must be performed by a recognized expert.
An expert is a person who has sufficient knowledge in the field of the hydraulic hoses due to
their technical training and experience.
163
Maintenance
The expert must be familiar with the relevant health and safety regulations, accident preven-
tion rules, technology guidelines and best practices, to an extent that the expert can judge
whether hydraulic hoses are in a safe state for use.
Possible faults:
The following examples demonstrate the most important faults which require an urgent
replacement of the hoses.
The outer layer of the hose pipe is damaged up to the insert (Chafe marks, cuts or
cracks).
The outer layer is brittle (cracks in hose material).
The hose pipe is deformed, or deforms in the pressureless or pressurized state, and/or
in case of bending, e.g. separation of layers, bubble formation, crushing or kinks.
The hose pipe is leaky.
The hose pipe slips out of the fitting.
The fitting is damaged or deformed (strength of fitting or connection hose/fitting
impacted).
The fitting is corroded - impact on functionality and strength.
The product lifetime has expired (see manufacturing date on hose fitting).
Replacing hoses.
When replacing hoses the following must be observed:

Only use original spare parts.
This helps to ensure that the hoses have the correct load-bearing capacity and that the
length and/or fittings match.
Keep to the original installation position, do not modify hose clamps or the bend radius.
Safety instructions:
Make sure that hoses do not contact substances that can cause damage, e.g. acids, lyes, sol-
vents.
Do not use ozone-emitting lighting fixtures or devices that generate sparks in the immediate
vicinity.
Avoid reuse of hoses.
The first use of the hose can impact the hose material's characteristics so that reuse becomes
dangerous.

Maintenance
6.1.3 Manometer
Depending on the machine type, manometers for checking hydraulic pressure may be fitted at
various positions (e.g. for cores).
Manometer
Shut-off valve
Open the manometer shut-off valve only for the pressure test!
Then close the shut-off valve to prevent damage to the manometer!
165
Maintenance
6.1.4 Hydraulic oil change

Under normal circumstances, a hydraulic oil change must be made at maintenance interval 4.
Previous practical experience has shown that speed machines may be operated under very
different operating conditions and production cycles. An oil change may be necessary earlier
in individual cases. It is therefore essential that the oil quality is continuously checked.
We recommend having the used oil status checked at 3 month intervals by your hydraulic oil
vendor and changing the hydraulic oil based on your vendor's recommendations!
CAUTION!
Danger to environment, danger of fire!

When draining and disposing of use oil, avoid pollution and avoid endan-
gering your environment. Follow local waste-disposal laws when drain-
ing and disposing of oil.
Change process:
1. Dismount the filling and venting filter
2. Use a suction pump to draw off the used oil, and drain the remaining oil via the oil drain
screw (at the bottom of the oil tank) into catchment trays
3. Dismount cleaning cover on the oil tank
4. Clean oil tank walls and floor to remove residue (e.g. with diesel oil)
5. The used oil must be disposed of legally, in line with waste-disposal laws
6. Screw in oil drain plug
7. Mount cleaning cover on the oil tank
8. Mount the filling and venting filter
9. Top up with hydraulic oil
6.1.5 Hydraulic oil filling

Do not run the machine unless it has been topped up with hydraulic oil.
Zinc-based hydraulic oil is used for commissioning at the factory. The machine is typically
delivered with an empty oil tank. Owner must use zinc-based hydraulic oil with same charac-
teristics when filling with oil or on oil change!
Note!
Use hydraulic oil with approved viscosity „ISO VG46” only.

Maintenance
Hydraulic oils zinc-based
norm DIN 51524-2

ISO VG46
OMV HYD HLP 46

OMV HYD HLP-SH46
ARAL VITAM GX 46
AGIP OSO 46
ENERGOL HLP HM 46
HYSPIN AWS 46
ASTRON HLP 46
NUTO H 46
167
Maintenance
Hydraulic oils zinc-based
DTE 25
TELLUS 46
TELLUS S2 M 46
SUNVIS 846 WR
RADON OIL HD C 46
TOTAL AZOLLA ZS 46
Note!
When changing the lubricant make, make sure you completely replace the hydraulic oil.
If you need to top up with lubricant other than the one employed, contact the oil vendor to
ensure miscibility.
The oil fill volume is noted on the oil type plate on the machine, or in the technical data docu-
mentation provided with the footing plan.
CAUTION!
Danger of overfilling due to residual oil in clamping unit!

If the clamping unit is closed, fill only to minimum level in sight glass.
Filling process:
1. Open the filler cap on the oil tank
2. Preferably use a filling device fitted with a fine filter of < 10 µm to fill the oil tank.
The hydraulic oil filling must correspond to the following contamination class:
- Pursuant to DIN 51524-2: HLP
- Pursuant to ISO 4406: 16/13
- Pursuant to NAS 1638: 8/7
The oil fill level must be in the top third of the sight glass while the clamping unit is
open, but in the bottom third when the clamping unit is closed!
3. Screw the filler cap back on the oil tank

4. Vent hydraulic system

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

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

If you intend to change to non-zinc hydraulic oil, you must flush the system first.
CAUTION!
Danger of damage to hydraulic equipment.

Mixing of zinc-based and non-zinc hydraulic oil must be avoided.
Suitable non-zinc hydraulic oils:
169
Maintenance
Non-zinc hydraulic oils
norm DIN 51524-2

ISO VG46
HYD HLP AL 46
ARAL VITAM GF 46
DTE EXCEL 46
TELLUS S 46
TELLUS S3 M 46
AZOLLA AF 46
Procedure for changing from zinc-based to non-zinc hydraulic oil:

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

Drain used oil
Fill with non-zinc hydraulic oil

Maintenance
6.2 Oil temperature control

Die Hydrauliköltemperatur soll immer 45 °C (113 °F)betragen.
Oil temperature control
Info Panel
+ Zone Control parame-
Set value
Maximum temperature
Minimum temperature
If the oil temperature is below or drops below the configurable minimum temperature while the
motors are running, a hydraulic oil preheating program automatically starts with the following
message:
Oil temperature too low for automatic mode
Cause Oil temperature below minimum temperature (or below target value
after control unit is switched on).
Effect Automatic mode locked until minimum temperature reached.
Oil temperature too high
Cause The hydraulic oil has exceeded the set maximum temperature.
Effect Alarm lamp, production stop.

If the temperature rises above 70 °C (158 °F), the motor and cooling
water valve switch off.
Remedy Open cooling water, check cooling water supply and temperature,
clean oil cooler.
171
Maintenance
No oil temperature change
Cause Temperature must rise by at least 2 °C (3.6 °F) within 5 minutes dur-
ing oil preheating.
Possible problem with thermocouple or hydraulic system
Effect Motor stops
Example: Pressure and volume control for a oil preheating pump
Oil heating
Oil preheating pressure Volume
+
Factory defaults, see also Var Monitor, OilHeating Group.

Maintenance
6.2.1 Oil cooler

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

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

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

the red button pops out
a message appears on screen
hydraulic oil has been changed
173
Maintenance
During cold starts the red button on the indicator may pop out.
Do not push the red button back in until operating temperature has been reached.
If it immediately pops out again (indicating excessive differential pressure), make sure you
replace the filter element.
Message:
Check oil filter, check high pressure filter, check return filter, no
oil filtration,
Cause +24V not applied to digital input F2, oil filter contaminated, motor for
auxiliary flow filtration switched off.
Effect Machine stops active cycle, alarm lamp flashes. Motor ramps off,
heating ramps down.
Remedy Check oil filter and filter motor.
Note!
Exercisecaution if you only need to replace filter elements infrequently or not at all; the
contamination indicator may not be showing you when to change the filter. If the con-
tamination indicator is working properly, you can assume that the filter element is
defective, or that the bypass valve is not closing properly, possibly on account of con-
taminants.

Maintenance
[1] Mechanical soiling indicator (red button)

[2] Gasket
[3] Screw-on cartridge
[4] Press in the red button.
Replace filter element:
Observe notes on filter housing label

1. Use a suitable catchment tray.
2. Use strap wrench to remove screw-on cartridge - turn anti-clockwise
3. Check whether the order number on the new screw-on cartridge matches the order
number on the type plate
4. Oil the seal on the screw-on cartridge slightly
5. Follow printed instructions to fit the screw-on cartridge
6. Press in red button
You cannot clean filter elements! Always fit new filter elements!
CAUTION!
Environmental hazard!
Follow waste disposal regulations when disposing of used filter ele-
ments.
Order replacement filter elements and keep in stock! [See Spare parts on page 195.]
6.4 Auxiliary flow filtration

In this case, filtration and cooling of the hydraulic oil do not occur on the main line, but in a sep-
arate cooling circuit with a separate pump.
Filtration is always active while the pump motor is running, but can also be started separately
to filter fresh oil.
Oil filtration only

Oil preheating
+
Oil filtration only:

The program switch Only oil filtration must be switched on manually and/or switches on auto-
matically when the oil level becomes too low.
175
Maintenance
Oil filtration active
Effect Main motor does not start.
Remedy You may need to top up with oil, filter oil for sufficiently long period,
switch off oil filtration.
Filtering fresh oil:

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

A separate input is used to monitor the external oil filter station for filter contamination.
If the input ’External oil filter station’ is not set to +24V, the machine will finish the current cycle
and switch to malfunction.
Check external filter station
Cause Hydraulic oil filter on external oil filter station contaminated.
Effect The machine will finish the current cycle and stop, the alarm lamp will
flash.
Remedy Check filter and replace if needed.

Maintenance
6.6 Checking and filling the membrane accumulator

Membrane accumulators for the hydraulics on the injection molding machine mainly serve to
actuate shut-off nozzles.
WARNING!
Danger of fatal injury due to explosion!

Never fill with oxygen or air!
Use only nitrogen to fill the membrane accumulator.
Before checking, and before topping up with nitrogen, close the shut-off
valve to separate the membrane accumulator from the hydraulics sys-
tem and to relieve pressure.
Keep to the following steps for checking and filling using the filling and testing device, FTU-1:
Testing
1. Relieving the pressure on the membrane accumulator hydraulics side.

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

5. Close the relief valve on the FTU-1 tight.
6. On the FTU-1 turn the spindle clockwise to open the gas valve on the machine's mem-
brane accumulator.
The manometer will now show the accumulator's gas pressure.
The pressure in the membrane accumulator should be 40 bar (580 psi). If the pres-
sure is too low, or the accumulator is empty, top up with nitrogen (see Nitrogen Fill-
ing).
7. If the pressure is too high, you can let off some nitrogen via the relief valve.
Carefully open the relief valve until the pressure drops to 40 bar (580 psi).
177
Maintenance
8. If the pressure is 40 bar (580 psi), turn the spindle on the FTU-1 anti-clockwise to close
the gas valve on the accumulator.
9. Use the relief valve to release the pressure on the FTU-1 and unscrew to remove. Make
sure the o-ring is in place and not damaged.
10. Use leak detector spray to check that the gas valve is tight.
11. Fit the protective cap, observing tightening torque.
Nitrogen Filling
1. Perform items 1 through 6 of the previously described check.

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

on machine
6. Close the pressure reduction valve.

7. Carefully open the shut-off valve on the nitrogen cylinder, and slowly set the gas filling
pressure at the pressure reduction valve to avoid damage to the gas valve on the blad-
der accumulator.
8. Interrupt filling periodically to check the current filling pressure on the manometer.
9. Repeat this procedure until you have reached the required gas filling pressure.
10. After allowing the temperature to adjust to match the ambient temperature, check the
filling pressure again, and correct if needed.
11. Close the shut-off valve on the nitrogen cylinder, and remove the filling hose.
12. If the pressure is too high, you can let off some nitrogen via the relief valve.
Carefully open the relief valve until the pressure drops to 40 bar (580 psi).
13. If the pressure is 40 bar (580 psi), turn the spindle on the FTU-1 anti-clockwise to close
the Allen screw.

Maintenance
14. Use the relief valve to release the pressure on the FTU-1 and unscrew to remove.
15. Use an Allen key (size 6) to tighten the Allen screw to a torque of 20 Nm (14.8 lbf.ft).
Make sure the o-ring is in place and not damaged.
16. Use leak detector spray to check that the gas valve is tight.
17. Fit the protective cap, observing tightening torque.
Before starting up the injection molding machine, you must have the pressure accumulator
and safety valve approved on site by your local authorities.
Present the following certificates to the authorities!

The test certificate for the pressure accumulator is in chapter: Plans and Protocols [See Pres-
sure accumulator test certificate on page 211.]
CAUTION!
The owner must organize regular reinspections.
Refer to your national authority for information regarding the type of and intervals
between tests.
179
Maintenance
7 Compressed air unit
WARNING!

All hoses on the injection molding machine must be checked at least
quarterly to ensure they are safe for use.
This test must be performed by a recognized expert.
An expert is a person who has sufficient knowledge in the field of the pneumatics due to their
technical training and experience.
The expert must be familiar with the relevant health and safety regulations, accident preven-
tion rules, technology guidelines and best practices, to an extent that the expert can judge
whether the compressed air lines are in a safe state for use.
Possible faults:
The following examples demonstrate the most important faults which require an urgent
replacement of the compressed air line.
The compressed air line is damaged (wear and tear).
The compressed air line is deformed, or deforms in pressureless or pressurized state,
and/or in case of bending, e.g. bubble formation, crushing or kinks.
The compressed air line is leaky.
Replacing compressed air lines.
When replacing compressed air lines, the following must be observed:

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

Maintenance
8 Air filter unit

The compressed air line must be of the same dimensions as the maintenance unit it services.
The fitting direction is indicated by an arrow (direction of flow).
WARNING!
Danger due to accidental functional movements.

Before commencing maintenance and repair work, close the shut-off
valve on the air maintenance unit.
The air maintenance unit was factory set to ensure perfect working of
the pneumatic equipment and must not be modified.
[1] Handwheel operating pressure

[2] Manual shut-off valve
[3] Manometer
[4] Locking of filter tray
[5] Filter tray
[6] Display for the condensate level
(Maximum fill height)
[7] Condensate drain (orange button)
Draining condensate:
Once a condensate level of approx. 10 mm (0.4 in) below the filter element has been reached,
you must drain the condensate manually.
1. Use a suitable catchment tray.
2. Drain condensate by pressing orange button.
3. Dispose of condensate legally, in line with waste-disposal laws.
Change filter elements every 2 years or when pressure drop reaches 1 bar (14.5 psi).
181
Maintenance
Change filter element:

1. Close the shut-off valve.
2. Venting the system and devices.
3. Pull filter tray lock downwards and rotate to marking on filter tray.
4. Now unscrew and remove the filter tray anti-clockwise.
5. Replace the filter element by a new one.
6. Mount the components in reverse order (hold the new filter element at the bottom end
only).
Venturi nozzles
Pay attention to that no oil or dirt gets into the venturi nozzles (vacuum generators). The clean-
ing occurs by blowing through the venturi nozzles.

Maintenance
9 Software updating
You will need a software update if purchasing an option or changing to a current machine/robot
software. This is implemented separately for the machine (update) and robot (robotupdate).
The update file can be provided by email, downloaded from the Engel FTP server or on a USB
stick.
If you receive the software update by email or as a download from the Engel FTP server, the
update file will be zipped (ZIP file). Unzipping the file on a USB stick is described below.
9.1 Preparing the software update

You need a PC with a USB interface, and a formatted and empty USB stick with at least 1 GB
memory for this. [See Restore software with backup copy on page 185.]
1. Copy the Zip file (xxxxxx_update.zip and/or xxxxxx_robotupdate.zip) to the desktop.
2. Insert the USB stick into the USB slot.
3. Double click the Zip file and extract on the USB stick.
In the Program WinZip (or similar tool), select all files.
Click on extract.
Extract to: Select drive with USB stick (enable checkbox ’Use path’ ).
For the execution click on Extract.
4. In the Windows explorer execute Eject change data carrier.

Do not remove the USB stick until ejecting has been complete without error.
Examples of extracted Zip files on the USB stick:

(Software version as of 2.xx; machine and robot update)
USB stick formatting:

The USB stick must be formatted to ensure an error-free update.
You need administrative privileges on the PC.

1. Plug the USB stick (at least 1 GB) into the PC.
2. Open Windows Explorer.
3. Select the USB-Stick drive with the right mouse button.
4. SelectFormat.
5. Format with the FAT file system.
183
Maintenance
9.2 Carry out software update

The software updating process, from software version V2.xx, automatically creates a back-up
copy of the Flash card (harddisk0) on the USB stick.
Software updating:
1. Insert the USB stick with the update file into the machine.
2. In the data dialog, select the screen key Setup - Software update.
Data dialog
Info Panel
\harddisk 0 Active parts data set ENGEL standard
Data set attributes

Name
System name
Author
System flash card
Software update
3. The control unit will display the available drive with the update.
Software update
Available drives \usbmassstorage
Cancel Help Execute
4. Press Execute to confirm and launch the update:

Store the parts data set and the machine data set on ’harddisk0’/Data (name the
parts data set BACKUP_xxxxx).
Create a complete copy of ’harddisk0’ on the USB stick (takes a few minutes).
Software updating.
Delete the update file from the USB stick.
Restart twice (can take up to 15 minutes).
Messages that may be output in the data dialog window during the software update:
No valid update found
No USB stick connected to the machine.

The USB stick has an incorrect file structure; the root directory may only contain the
update or robotupdate files.
Update failed, incorrect serial number!
The software update is not intended for this machine!
Update failed, not enough free memory!
The USB stick for backup storage of the ’harddisk0’ does not have enough free
memory!

Maintenance
Error occurred during update (see log files)!
Software update interrupted or a software error has occurred! Please check the HMI log
entry in update.log and contact ENGEL Service.
HMI log entry - update.log
Open screen page Setup and select screen key Screens.
In the screens window, select Version display and press OK to confirm.
Select the HMI log entry tab and the update.log screen key.
Version display
Version information License informa- HMI log entry
to top to bottom
The update.log file documents all procedures performed by a software update.
9.3 Restore software with backup copy

If the software update fails or the machine malfunctions following a software update, restore
the original state with the backup copy.
WARNING!
Danger of fatal injury due to electrical voltage in the switch cabinet!

Switch off at main switch and secure against re-enabling.
This work may only be carried out by a qualified electrician.
Restoring the system Flash card (harddisk0)
The backup copy of the system Flash card will be in a subdirectory called backup_hd0on the
USB stick with the update file. Use a PC to copy the content of the file to a compact flash
(Toshiba THNCF512MDGI), and insert the card into the CPU card slot.
Read parts data and machine data:
185
Maintenance
1. On ’harddisk0’ select the Data directory.

2. Load the Engel machine data set.
3. Switch the control voltage off and back on.
4. Load the parts data set (BACKUP_xxxxx).
Restoring the Submaster system Flash card

A backup copy of the Submaster software is only created when the Submaster card software
is updated! If a backup copy is not present, then no software update of the Submaster card has
been carried out.
The backup copy will be in the root directory with the name _submastercardbackup. All Sub-
master cards in a machine use the same software, so you can restore the same backup copy.
Procedure:
1. Copy the backup copy _submastercardbackup to the PC.
2. Remove the compact flash from the Submaster card.
3. Plug the compact flash into the PC (use a compact flash card reader) and delete all data
from the compact flash.
4. Copy the content of the backup copy _submastercardbackup to the compact flash.
5. Insert the compact flash into the Submaster card.
Note!
The Submaster card is a 2 or 3 CPU card and can be seen in the wiring diagram.

Maintenance
9.4 Firmware - Update

The firmware (= system software) includes the software for visualization, sequence editor, etc.
When to the software update in addition a ’FWU.ZIP’ file is delivered, a firmware update must
be carried out.
1. Unpack file FWU.ZIP on a separate Flash card.
As result on the Flash card the directory ’FWU’ must be created. This includes the nec-
essary files for the firmware update (iu450_fw_0.13.bin, di470_fw_1.12.bin, etc.)
2. Now insert this Flash card in the front slot address (hard disk 1) of the machine control
unit.
3. Switch the control voltage off and back on.
At the run-up of the control unit the configuration file is recognized automatically.
4. Starting of the update process by pressing the soft key ’Start Update’ on the touch
screen. The central screen area displays the status information during the update pro-
cess (Update of IU450 in progress ...).
5. After successful update the following message appears:
’please remove harddisk 1 and restart’.
6. Remove the Flash card from hard disk 1.
7. Switch the control voltage on/off to load the new firmware.
187
Maintenance

Options
Options
189
Options

Disassembly
Disassembly
Before transporting the machine, the robot and peripheral units must be dismounted. Refer to
the vendor's instructions to do so.
WARNING!
Danger of fatal injury in case of improper dismounting!

Skilled staff are required to dismount the machine.
controls!
Main switch, type plate and connections of a Duo.
3 2
[1] Connection cooling water return

[2] Connection cooling water feed
[3] Mains connection
[4] Main switch
[5] Machine type plate
191
Disassembly
1 Disconnecting
WARNING!
Danger of fatal injury due to electrical voltage and high pressure!

A qualified electrician is required to disconnect the machine from the
mains power supply.
Switch off the mains power supply before disconnecting the machine,
and secure against switching on.
Make sure power lines have zero potential before disconnecting.
Make sure media lines have zero pressure before disconnecting.
Procedure:
1. Bring clamping unit on transport position (see also transport sketch). Open moving mold
fixing platen.
2. Switch off motor
3. Secure injection unit for the transport. [See Remove the transportation safeguard on
page 48.]
4. Block media pipings and check them for pressure freedom!
5. Disconnect cooling water
6. Blow out cooling circuits with compressed air
Open all the flow control devices
Open the cooling water valve
Purge the cooling circuit with compressed air.
7. Disconnect compressed air

8. Switch off main switch
9. At the machine drain the used oil from the tank in a reservoir suitable for this purpose or
pump it into it.
10. Switch off and disconnect the power supply for the plant.
11. Disconnect electric interfaces.
12. Disconnect hydraulic interfaces. [See Transportation on page 43.]
Place oil catchment tray under the hydraulic hoses - dispose of escaping oil into the
appropriate container .
Close hydraulic hoses with hydraulic screw couplings!
13. Separate mechanical interfaces. [See Transportation on page 43.]
Note!
It is very important to blow out the cooling circuits and drive motor cooling properly when the
weather is cold. Danger of frost damage!

Disassembly
2 Removal of the machine

Before lifting the machine, observe the transport sketch in the chapter Installation and Com-
missioning. [See Transportation on page 43.]
WARNING!

Skilled staff, who are familiar with machine transportation tasks, are
required to transport the machine.
Use lifting gear and cables with sufficient load-bearing capacity. For weight refer to type
plate on machine or to Plans and Protocols chapter (technical data, foundation plan).
Only use the marked lifting eyes for transportation. [See Transportation on page 43.]
The injection unit and the clamping unit must be lifted and transported horizontally (lon-
gitudinally and transversely). Adjust the lifting gear length accordingly.
Make sure the cables are of sufficient length (taking the maximum spread of the cables
on the crane hooks into consideration 60°).
Before lifting the machine, check the routing of the cables from the lifting eyes to the lift-
ing gear.
3 Disposal
CAUTION!
Environmental hazard!
Used oil and certain machine components can endanger the water sup-
ply, and cause major environmental damage in case of improper dispos-
al!
All machine components and parts are subject to special collection and waste disposal regu-
lations.
Make sure you observe national waste disposal regulations!
193
Disassembly

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

The spare parts list is used to find order numbers; it is located on the machine CD in PDF for-
mat.
Component numbers on the design drawings or circuit diagrams can be used to find the cor-
responding order number in the spare parts list.
2.1 Design drawings

The design drawings are used to identify spare parts; they can be found in printed form in the
Service manual machine and in PDF format on the machine CD.
CAUTION!
Danger of damage to equipment!

Do not use design drawings as instructions for maintenance and repair
work.
The following design drawings are intended solely for the purpose of
identifying and ordering spare parts.
Component numbers on the drawings can be used to find the corresponding order number in
the spare parts list.
195
Spare parts
Example:
Searching for an order number for a non-return valve with component number and drawing
number of the design drawing.
1. Select the design drawing for the barrel on the machine CD.
2. Search for and make a note of the number of the non-return valve on the design draw-
ing.
The non-return valve
has number 100 and
consists of 3 parts (100/
1, 100/2 and 100/3).
In this case, the compo-
nent number for the
barrel is not present.
3. If the component number is missing on the drawing, then make a note of the drawing
number/name for the barrel.
4. Open the spare parts list on the CD.

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

Spare parts
2.2 Hydraulics schematic

The hydraulics schematic is used for troubleshooting and to identify spare parts. It exists in
printed form in the switch cabinet and in PDF format on the machine CD.
DANGER!

Before opening the switch cabinet, switch off at main switch and secure
against switching on.
The hydraulics schematic contains not only the schematic, but also the drawings for the indi-
vidual hydraulic blocks.
The component numbers and block numbers can be used to find the corresponding order
number in the spare parts list.
Example:
Searching for an order number for a hydraulic directional valve on the pump block, with the
component and block numbers from the hydraulics schematic.
1. On the PC, open the hydraulics schematic on the machine CD.

2. Open the drawing for the pump block and identify the valve. The Engel valve number
20115194 is also the order number.
Block number
3. You can also find the valve by entering the block number in the spare parts list of the CD.
Search
Note!
The hydraulic pump is not on the block drawing. The hydraulic pump is at the beginning of the
list for the hydraulic plant in the spare parts list of the CD.
197
Spare parts
2.3 Circuit diagram

The circuit diagram is used for troubleshooting and to identify spare parts. It exists in printed
form in the switch cabinet and in PDF format on the machine CD.
DANGER!

Before opening the switch cabinet, switch off at main switch and secure
against switching on.
Type designations or the names of devices can be used to find the corresponding order num-
ber in the spare parts list.
Example:
Searching for an order number for a semiconductor relay for the nozzle heater.
1. On the PC, open the circuit diagram on the machine CD.

2. Open the drawing for the nozzle heater.
3. You can find the semiconductor relay by entering the type designation RM1A48 in the
spare parts list of the CD. The material number is 02206-0178.
Search

Spare parts
2.4 Ordering spare parts without a material number

If you are unable to determine the material number so that you can order a spare part, send
an email with the following content to your local service point:
Machine number
Machine type
Copy of drawing or schematic with the desired device highlighted.
Example: thermocouple for nozzle heater
Photographs are also helpful for identifying spare parts.
Note!
If you order spare parts by telephone, first make a note of the machine number.
199
Spare parts

Plans and Protocols
Plans and Protocols
1. Technical data
2. Foundation plans
3. Mold mounting dimensions
4. Certificates
5. Pressure accumulator test certificate
201
Plans and Protocols

Plans and Protocols
1 Technical data
The technical data are also provided in PDF format on the CD.
203
Plans and Protocols

Plans and Protocols
2 Foundation plans
The base plan is also provided in PDF format on the CD.
205
Plans and Protocols

Plans and Protocols
3 Mold mounting dimensions

The mold mounting dimensions are also provided in PDF format on the CD.
207
Plans and Protocols

Plans and Protocols
4 Certificates
The protocols and certificates are only included in the service manual.
4.1 EC declaration of conformity
4.2 Declaration of incorporation
4.3 Noise emission report
209
Plans and Protocols

Plans and Protocols
5 Pressure accumulator test certificate

The inspection document on the CD is in PDF.
211
Plans and Protocols

Plans and Protocols
213
Plans and Protocols

Additional equipment
If vendor documentation is required due to a special version or special equipment on the injec-
tion molding machine, the appropriate description will follow in this chapter or on CD!
215

Special programs
Special programs
217
Special programs

Symbols Air filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Aligning the stationary and moving mold fixing platens . . . .55
*Acknowledge safety gate 3 . . . . . . . . . . . . . . . . . . . . . . . 138
*Acknowledge safety gate 4 . . . . . . . . . . . . . . . . . . . . . . . 138 Anchor safety guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Attaching mold to crane . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
*Acknowledge safety gate x . . . . . . . . . . . . . . . . . . . . . . . . 30
*Acknowledgement contactor 3 defective . . . . . . . . . . . . 138
*Acknowledgement contactor 4 defective . . . . . . . . . . . . 138 B
*Acknowledgement contactor x defective . . . . . . . . . . . . 132 Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
*Check external filter station . . . . . . . . . . . . . . . . . . . . . . 176
*Check high-pressure filter . . . . . . . . . . . . . . . . . . . . . . . . 174 C
*Check oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Calculate mold dimensions . . . . . . . . . . . . . . . . . . . . . . . . .81
*Check return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Calibrating the nozzle stroke . . . . . . . . . . . . . . . . . . . . . . .112
*Clamping unit disconnected safety gate x not open . . . . . 30 Carry out software update . . . . . . . . . . . . . . . . . . . . . . . . .184
*Clamping unit maintenance safety gate x open . . . . . . . 134 Centering of mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
*Clamping unit safety gate 3 defective . . . . . . . . . . . . . . . 137 Centering the nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
*Clamping unit safety gate 3 interrupts cycle . . . . . . . . . . 136 Central oil lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
*Clamping unit safety gate 3 open . . . . . . . . . . . . . . . . . . 136 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
*Clamping unit safety gate 4 defective . . . . . . . . . . . . . . . 137 Changing a screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
*Clamping unit safety gate 4 interrupts cycle . . . . . . . . . . 136 Changing from zinc-based to non zinc-based oil . . . . . . . .169
*Clamping unit safety gate 4 open . . . . . . . . . . . . . . . . . . 136 Changing the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
*Clamping unit safety gate interrupts cycle . . . . . . . . . . . . 25 Check machine - EVER-Q . . . . . . . . . . . . . . . . . . . . . . . . .121
*Clamping unit safety gate open . . . . . . . . . . . . . . . . . . . . 25 Checking and filling the membrane accumulator . . . . . . . .177
*Clamping unit safety gate x (closing safety) defective . . 128 Checking the coaxiality of the two mold halves . . . . . . . . . .94
*Clamping unit safety gate x acknowledgement key actuated for Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Cleaning after installation . . . . . . . . . . . . . . . . . . . . . . . . . .60
*Clamping unit safety gate x acknowledgement key actuated too Closing area acknowledgement . . . . . . . . . . . . . . . . . . . . . .26
quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Closing behavior of mold in different clamping mechanisms 96
*Clamping unit safety gate x defective . . . . . . . . . . . . . . . 127 Compressed air quality . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
*Clamping unit safety gate x open-close . . . . . . . . . . . . . . 25 Compressed air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
*Close safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Compressed-air line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
*Contact point not within stroke limits . . . . . . . . . . . . . . . 111 Connecting the frames of the clamping unit and the injection unit
*Emergency-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
*Hydraulic closing safety cartridge defective . . . . . . . . . . 129 Connecting the injection unit to the stationary mold fixing platen
*Hydraulic closing safety defective . . . . . . . . . . . . . . . . . . 128 72
*Locking safety gate defective . . . . . . . . . . . . . . . . . 141, 143 Cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
*Locking safety gate not moved out . . . . . . . . . . . . . . . . . 143 Cooling water consumption . . . . . . . . . . . . . . . . . . . . . . . . .66
*Lubrication 1/2 pressure not built up . . . . . . . . . . . . . . . . 159 Cooling water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
*Lubrication 1/2 pressure not relieved . . . . . . . . . . . . . . . 159 Correct mounting of molds . . . . . . . . . . . . . . . . . . . . . . . . . .89
*Lubrication oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
*Maintenance interval x . . . . . . . . . . . . . . . . . . . . . . . . . . 117 D
*Mechanical closing safety contacts . . . . . . . . . . . . . . . . 146 Danger of damage to hydraulic equipment. . . . . . . . . . . . .170
*Mechanical closing safety x defective . . . . . . . . . . . . . . . 145 Danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
*Mechanical closing safety x moved in . . . . . . . . . . . . . . . 32 Declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . . .209
*Mold movement wrong . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Design drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
*No oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Disconnecting cooling water . . . . . . . . . . . . . . . . . . . . . . .192
*No oil temperature change . . . . . . . . . . . . . . . . . . . . . . . 172 Disconnecting the machine . . . . . . . . . . . . . . . . . . . . . . . .191
*Nozzle safety gate defective . . . . . . . . . . . . . . . . . . . . . . 129 Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . .193
*Nozzle safety gate open . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Distance between tie-bars . . . . . . . . . . . . . . . . . . . . 140, 142
*Nozzle stroke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . 111
*Nozzle stroke limitation x (limit switch) reached . . . . . . . 112 E
*Nozzle stroke limitation x reached . . . . . . . . . . . . . . . . . 112
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . .209
*Nozzle stroke transducer defective . . . . . . . . . . . . . . . . . 111 Electric connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
*Nozzle stroke transducer mounted incorrectly . . . . . . . . 110
Electric safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
*Oil filtration active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Emergency-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
*Oil level too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
*Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . 171
*Oil temperature too low for automatic mode . . . . . . . . . . 171
F
Firmware update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
*Open-close-acknowledge safety gate x . . . . . . . . . . . . . . 30
*Safety gate - safety strip - actuated . . . . . . . . . . . . . . . . . 28 Fix safety guarding on the injection molding machine . . . . .61
Floor anchorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
*Safety gate safety strip opening active . . . . . . . . . . . . . . 133
Foundation plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
*Safety guarding 3 acknowledgement time exceeded . . . 138
*Safety guarding 4 acknowledgement time exceeded . . . 138 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Functioning of the safety gates . . . . . . . . . . . . . . . . . . . . . .25
*Safety guarding x acknowledgement time exceeded . . . . 30
*Screw change safety gate open . . . . . . . . . . . . . . . . . . . 149
*Step safety active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 G
*Tank shut-off valve(s) closed . . . . . . . . . . . . . . . . . . . . . 163 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
*Test step safety 1 (-4)! . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Guidelines for working on the injection molding machine . .22
A H
Additional equipements . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Air filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Hours of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
219
Hydraulic oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Safety gate locking . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 142
Hydraulic oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Safety gate on clamping unit side . . . . . . . . . . . . . . . . . . 135
Hydraulic oil overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Safety guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Hydraulics schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Safety guarding assembly instructions . . . . . . . . . . . . . . . . 60
Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
I Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Injection unit machine pedestal . . . . . . . . . . . . . . . . . . . . . 46 Setting up the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Setting up the nozzle stroke transducer . . . . . . . . . . . . . . 107
L Software updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Spare part drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Leveling the injection molding machine . . . . . . . . . . . . . . . 51
Starting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Locking of electric safety gate (from DUO 800) . . . . . . . . 141 Step safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Survey safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Locking of manual safety gate (from DUO 800) . . . . . . . . 139
Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
T
M Tank shut-off flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Machine CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Machine overview DUO . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance EMERGENCY STOP buttons . . . . . . . . . . . 125 Throughput controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Transport of the protection door . . . . . . . . . . . . . . . . . . . . . 60
Maintenance of automatic safety gate . . . . . . . . . . . . . . . 133
Transport safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Maintenance of moving safety gates . . . . . . . . . . . . . . . . 126
Maintenance safety gate . . . . . . . . . . . . . . . . . . . . . . . . . 133 Transport sketch for clamping unit . . . . . . . . . . . . . . . . . . . 44
Transport sketch for injection unit . . . . . . . . . . . . . . . . . . . 45
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maintenance step safety . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Mandatory Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 V
Mechanical closing safety . . . . . . . . . . . . . . . . . . . . . .32, 144 Vent hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Mold anti-twist safeguard (rotational centering) . . . . . . . . . 88 Ventilation pressure pad . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Mold mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . 207 Venturi nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Mount mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Mounting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 W
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
N water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Noise emission report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Nozzle centering - horizontal . . . . . . . . . . . . . . . . . . . . . . . 79
Nozzle stroke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
O
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Oil temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Operating pressure compressed air . . . . . . . . . . . . . . . . . . 68
Operating pressure compressed air to set . . . . . . . . . . . . . 69
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Ordering spare parts without a material number . . . . . . . 199
Overview of lubricants circulating oil . . . . . . . . . . . . . . . . 160
P
Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pictographs for North America . . . . . . . . . . . . . . . . . . . . . . 18
Plans and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Preparing the software update . . . . . . . . . . . . . . . . . . . . . 183
Pressure accumulator test certificate . . . . . . . . . . . . . . . . 211
Prohibitory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
R
Removal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Remove the clamping unit transport safety brackets . . . . . 49
Remove the transportation safeguard . . . . . . . . . . . . . . . . 48
Replacing a nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Residual dust content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Residual oil content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Residual water content . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Restore software with backup copy . . . . . . . . . . . . . . . . . 185
S
Safeguarding closing mechanism . . . . . . . . . . . . . . . . . . . 138
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ENGEL AUSTRIA GmbH. 4311 Schwertberg
tel: +43.(0)50.620.0 fax: +43.(0)50.620.3609
e-mail: service@engel.at www.engelglobal.com

Manual de Operacion Maquinas ENGEL

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Manual de Operacion Maquinas ENGEL

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duo

Service Manual - Machine

Manufacturer: ENGEL AUSTRIA GmbH

e-mail: service@engel.at www.engelglobal.com

Person responsible for Mörwald Johann

INSTALLATION AND COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SETTING UP FOR INJECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

SPECIAL PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Structure of the system documentation:

Instruction Manual - Machine

Service manual - Machine (Commissioning, Maintenance)

Operator Manual - Machine (Operation)

Manual CD contains the following documents in PDF format: Operator,

Instruction Manual - Robot

Service manual - Robot (Commissioning, Maintenance)

Operator Manual - Robot (Operation)

Manual CD contains the following documents in PDF format: Opera-

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

Information on additional equipment is located in the chapter Additional Equipment.

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2 North American Applied standards and guidelines

ANSI/SPI B151.1 Plastics Machinery - Horizontal Injection Molding Machines - Safety

ANSI/RIA/ISO Industrial robots and robot systems - Safety requirements

NFPA79 Electrical standards for industrial machinery

3 Applicable European standards and regulations

2006/42/EG Machinery Directive

2006/95/EG Low Voltage Directive

2004/108/EG EMC Directive for Electromagnetic Compatibility

EN ISO 12100-1 Machine Safety

EN ISO 12100-2 Machine Safety

EN ISO 13857 Machine Safety, Safety Distances

EN 201 Safety Information for Injection Molding Machines

EN ISO 13850 Machine Safety, EMERGENCY STOP Equipment

EN 60204-1 Machine Safety, Electrical Equipment for Machines

EN ISO 10218 Industrial Robot Safety

Information marked with this symbol warns of possible danger which

Information marked with this pictogram warns of possible danger which

10 Service Manual - Machine | Version G/11/30/6/21

Possible dangers which can cause damage to the machine!

Operator Manual im Kapitel Bedienung.

Simple conversion examples

Category ISO unit Imperial unit Conversion factors

Stroke 100 mm 3,94 in 100 mm x 0.0394 = 3.94 in

Absolute tempera- 100 °C 212 °F 100 °C x 1.8 + 32 = 212 °F

Weight 100 g 3.53 oz.av 100 g x 0.0353 = 3.53 oz.av

Weight 100 kg 220.5 lb.av 100 kg x 2.205 = 220.5 lb.av

Force 100 kN 11.24 tf 100 kN x 0.1124 = 11.24 tf

Volume 100 l 58.1 gal/US 100 l x 0.581 = 58.1 gal/US

Torque 100 Nm 73.756 lbf ft 100 Nm x 0.7375 = 73.75 lbf ft

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7 Machine overview DUO

Clamping unit side Injection unit side

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[See Safety equipment functions on page 24.]

If you notice that safety equipment is defective,:

Danger from gases hazardous to health!

Danger of crushing due to moving components on the machine!

Danger of damage to equipment due to improper settings!

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Danger of fatal injury in case of improper maintenance!

Safety gate activated in sequence

Opening stroke in semi-automatic mode