MX1600 Manual

Technical Documentation
Operating Instructions for injection molding machine

MX-MC6 series
MX_MC6_V1.9_07.09.15_ENG
©KM
Original Operating Instructions

MX_MC6_V1.9_07.09.15_ENG
Reprinting, even of extracts, and translation require our express approval.

These operating instructions must not be distributed or used for the purpose of
©KM
competition without authorization, neither completely nor in part.

Due to continuous development, this documentation is subject to technical
alterations.
2
TECHNICAL DOCUMENTATION KraussMaffei Technologies GmbH
Table of Contents
0 Preface
1 Safety
2 Fundamentals of Injection Molding Technology
3 Specifications
4 Transport/Packaging
5 Installation
6 Operating/display elements
7 Commissioning
8 Operation of Machine
9 Rectifying Faults
10 Maintenance
11 Peripherals / Interfaces
12 Auxiliary devices
13 Taking machine out of service/Placing into storage/Disposal
14 Index
15 Parts lists/drawings
16 Electrical system
17 Hydraulics/Pneumatics
MX_MC6_V1.9_07.09.15_ENG
©KM
18 Supplier Documentation
19 Reports/Certificates
20 Revision Record
Table of Contents 3
KraussMaffei Technologies GmbH TECHNICAL DOCUMENTATION
MX_MC6_V1.9_07.09.15_ENG
©KM
4 Table of Contents
Table of Contents
0 Preface 0-25
0.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
0.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
0.1.2 Machine limits and products . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
0.1.3 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
0.1.4 User information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
0.1.5 Electromagnetic compatibility - EMC . . . . . . . . . . . . . . . . . . . . . . 0-26
0.1.6 Improper use/Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . 0-26
0.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-27
0.3 Structure of the technical documentation . . . . . . . . . . . . . . . . . . . . 0-28
0.4 Target group of the technical documentation . . . . . . . . . . . . . . . . . . 0-29
0.4.1 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-29
0.4.2 Technical documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-29
0.5 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30
0.6 User assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30
0.7 Warranty provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30
0.8 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-31
0.9 Download order-related MC6 software and documentation . . . . . . . . . . 0-32
0.10 KraussMaffei addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-36
0.11 Index of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-44
1 Safety 1-47
1.1 Symbol and explanation of notes . . . . . . . . . . . . . . . . . . . . . . . . 1-48
1.1.1 General symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
1.1.2 Instructions regarding specific hazards . . . . . . . . . . . . . . . . . . . . . 1-49
1.1.3 Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
1.2.1 Instructions contained in the operating manual . . . . . . . . . . . . . . . . . 1-53
1.2.2 Obligation on the part of the owner/operator . . . . . . . . . . . . . . . . . . 1-53
1.2.3 Obligation on the part of the personnel . . . . . . . . . . . . . . . . . . . . . 1-54
1.2.4 Training personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
1.2.4.1 Requirements in respect of the operating and maintenance personnel . . . . 1-55
1.2.4.2 Safety instructions for the operating and maintenance personnel . . . . . . . 1-56
1.2.5 Hazards in use of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
1.2.6 Hazards resulting from electrical energy . . . . . . . . . . . . . . . . . . . . 1-57
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1.2.7 Hazards resulting from hydraulic system . . . . . . . . . . . . . . . . . . . . 1-57

1.2.8 Hazards resulting from pneumatic system . . . . . . . . . . . . . . . . . . . 1-58
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1.2.9 Emission of harmful dusts and vapours . . . . . . . . . . . . . . . . . . . . 1-58

1.2.10 Hazards resulting from harmful fluids . . . . . . . . . . . . . . . . . . . . . . 1-58
1.2.11 Hazards during injection molding . . . . . . . . . . . . . . . . . . . . . . . . 1-59
1.2.12 Hazards during foaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
1.2.13 Dangers in mold area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
1.2.13.1 Hazards when changing the mold . . . . . . . . . . . . . . . . . . . . . . . 1-62
1.2.14 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
1.2.15 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
1.2.16 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
Table of Contents 5
1.2.17 Informal safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64

1.2.18 Safety measures during normal operation . . . . . . . . . . . . . . . . . . . 1-64
1.2.19 Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
1.2.20 Conduct in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
1.2.21 Safety when carrying out maintenance, repair and fault rectification work . . 1-66
1.2.21.1 Fundamental information on maintenance and repair work . . . . . . . . . . 1-66
1.2.21.2 Safety when working on electrical equipment . . . . . . . . . . . . . . . . . 1-67
1.2.21.3 Safety when working on hydraulic/pneumatic system . . . . . . . . . . . . . 1-68
1.2.22 Constructional modifications to the machine . . . . . . . . . . . . . . . . . . 1-69
1.2.23 Cleaning of machine and disposal . . . . . . . . . . . . . . . . . . . . . . . 1-70
1.3 Intervention or access points . . . . . . . . . . . . . . . . . . . . . . . . . 1-71
1.4 Safety at the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
1.4.1 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
1.4.1.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
1.4.2 Positioning of safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
1.4.3 Positioning of information and warning signs . . . . . . . . . . . . . . . . . 1-76
1.4.4 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
1.4.5 Emergency-stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81
1.4.6 Acknowledgement button . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82
1.4.7 Fault signal lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83
1.4.7.1 Fault signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83
1.4.7.2 Extended fault signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84
1.4.8 Master switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85
1.4.9 Protective panelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86
1.4.9.1 Protective panelling, mold area . . . . . . . . . . . . . . . . . . . . . . . . 1-86
1.4.9.2 Protective panelling nozzle area . . . . . . . . . . . . . . . . . . . . . . . . 1-87
1.4.9.3 Screw barrel protective panelling . . . . . . . . . . . . . . . . . . . . . . . 1-87
1.4.9.4 Protective panelling ejector area . . . . . . . . . . . . . . . . . . . . . . . . 1-87
1.4.10 Securing the work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
1.4.10.1 Service gate (safety gate core-pulling/clamping block) . . . . . . . . . . . . 1-88
1.4.10.2 Step-on safety grid (as of KM 1000 MX) . . . . . . . . . . . . . . . . . . . . 1-88
1.4.10.3 Safety strip, safety gate mold area . . . . . . . . . . . . . . . . . . . . . . . 1-88
1.4.10.4 Locking bolt (as of KM 1000 MX) . . . . . . . . . . . . . . . . . . . . . . . 1-88
1.4.10.5 Clamp safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
1.4.10.6 Door stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89
1.4.10.7 Robot work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90
1.4.10.8 Interface robot housing door, robot/injection molding machine according to
EUROMAP 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91
1.5 Inspection of safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92
MX_MC6_V1.9_07.09.15_ENG
1.5.1 Inspection of the EMERGENCY-STOP buttons and the EMERGENCY-

STOP circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93
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1.5.2 Inspecting the mold area safety gates (operator side and operator
rearside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
1.5.3 Inspection of locking bolt monitoring . . . . . . . . . . . . . . . . . . . . . . 1-96
1.5.4 Inspecting the safety strip . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96
1.5.5 Inspecting the service gate (core-pulling and clamping block) . . . . . . . . . 1-97
1.5.6 Inspecting the nozzle area safety gate . . . . . . . . . . . . . . . . . . . . . 1-98
1.5.7 Inspecting the ejector area safety gate . . . . . . . . . . . . . . . . . . . . 1-99
1.5.8 Checking the step-on safety grid . . . . . . . . . . . . . . . . . . . . . . . . 1-100
1.5.9 Inspecting the clamp safety circuit . . . . . . . . . . . . . . . . . . . . . . . 1-101
6 Table of Contents
1.5.10 Check of dynamic clamp safety circuit . . . . . . . . . . . . . . . . . . . . 1-102

1.5.11 Inspection of fixed protective panelling . . . . . . . . . . . . . . . . . . . . 1-103
1.5.12 Inspecting the robot safety gates (ZE) . . . . . . . . . . . . . . . . . . . . 1-103
1.6 Pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
1.7 Hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106
1.8 Safety test/safety instruction . . . . . . . . . . . . . . . . . . . . . . . . . 1-107
2 Fundamentals of Injection Molding Technology 2-109
2.1 Injection molding machines . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
2.1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
2.1.2 Injection unit MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
2.1.3 Injection units - combination options . . . . . . . . . . . . . . . . . . . . . 2-111
2.1.4 Clamping unit MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
2.2 Plasticizing (3-zone screw) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
2.2.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
2.2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
2.2.3 Screw types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
2.2.4 Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
2.2.5 Screw advance speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
2.3 Wear-intensive plastics and additives . . . . . . . . . . . . . . . . . . . . 2-116
2.3.1 Abbreviations of names of plastics . . . . . . . . . . . . . . . . . . . . . . 2-116
2.4 Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
2.5 Injection molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
2.5.1 Basic principles of injection molding . . . . . . . . . . . . . . . . . . . . . 2-118
2.5.2 Sequence of the injection molding process . . . . . . . . . . . . . . . . . . 2-118
2.5.3 Injection pressures (injection, holding and back pressure) . . . . . . . . . . 2-120
2.5.4 Energy-efficient operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
2.5.4.1 Machine, mold, peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
2.5.4.2 Machine setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
2.5.4.3 Production planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
2.6 Two-component injection molding technology . . . . . . . . . . . . . . . . 2-124
2.6.1 Basic procedural sequence for 2K-injection molding . . . . . . . . . . . . . 2-124
2.6.2 2K-injection molding procedures . . . . . . . . . . . . . . . . . . . . . . . 2-125
2.6.2.1 Distinguishing between procedures . . . . . . . . . . . . . . . . . . . . . 2-125
2.6.2.2 Compound injection molding . . . . . . . . . . . . . . . . . . . . . . . . . 2-126
2.6.2.3 Sandwich injection molding . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128
3 Specifications 3-129
3.1 Designation of the injection units . . . . . . . . . . . . . . . . . . . . . . . 3-130
MX_MC6_V1.9_07.09.15_ENG
3.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131

3.3 Requirements for the installation location, complete machine . . . . . . . . 3-151
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3.3.1 Ambient conditions for the electrical equipment . . . . . . . . . . . . . . . 3-151

3.3.2 Air specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3.4 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
3.4.1 Water specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
3.4.2 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154
3.4.2.1 Hydraulic fluid, specification . . . . . . . . . . . . . . . . . . . . . . . . . 3-154
3.4.2.2 Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-156
3.4.3 Lubricant specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
3.4.3.1 Lubrication specification for sliding surfaces on injection unit . . . . . . . . 3-158
Table of Contents 7
3.4.3.2 Lubrication specification, central lubrication system . . . . . . . . . . . . . . 3-159

3.4.3.3 Oil specification, electric screw drive . . . . . . . . . . . . . . . . . . . . . 3-160
3.5 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
3.6 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
3.6.1 Securing bolts on hydraulic components, tightening torques . . . . . . . . . 3-161
3.6.2 Bolts in high-temperature area, tightening torques . . . . . . . . . . . . . . 3-162
3.6.3 Bolts on barrel head, tightening torques . . . . . . . . . . . . . . . . . . . . 3-163
3.6.3.1 Screw connection, SP 4300 MX to SP 17200 MX . . . . . . . . . . . . . . . 3-163
3.6.3.2 Screw connection SP 24500 MX to SP 75000 MX . . . . . . . . . . . . . . 3-164
3.6.4 Tightening torques of securing bolts . . . . . . . . . . . . . . . . . . . . . . 3-165
4 Transport/Packaging 4-167
4.1 Safety precautions for transportation . . . . . . . . . . . . . . . . . . . . . 4-168
4.2 Requirements regarding personnel operating the machine . . . . . . . . . . 4-169
4.3 Transport/lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169
4.3.1 Attachment points, lashing points, dimensions and weights . . . . . . . . . . 4-170
4.3.1.1 Attachment points/lashing points, clamping unit KM 850 MX to
KM 1600 MX, land transport . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171
4.3.1.2 Attachment points/lashing points, clamping unit KM 850 MX to
KM 1600 MX, sea transport . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173
4.3.1.3 Clamping unit KM 2000 MX to KM 4000 MX . . . . . . . . . . . . . . . . . . 4-173
4.3.1.4 Attachment points/lashing points injection unit SP 4300 to SP 12000 . . . . . 4-174
4.3.1.5 Attachment points/lashing points injection unit SP 17200 to SP 24500 . . . . 4-178
4.3.1.6 Attachment points/lashing points injection unit SP 33000 to SP 55000 . . . . 4-179
4.3.1.7 Injection unit from SP 75000 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180
4.3.2 Means of transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180
4.3.3 Securing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-181
4.3.4 Delivery of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-183
4.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184
4.4.1 Removing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184
4.4.2 Repacking machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185
4.4.3 Examples of packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186
4.4.3.1 Sea transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186
4.4.3.2 Surface transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-188
4.5 Sea transport of machines with shrinking foil packaging . . . . . . . . . . . 4-189
4.5.1 Transport/load securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189
4.5.1.1 Transport on marine vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189
4.5.1.2 Containers for marine vessel transport . . . . . . . . . . . . . . . . . . . . 4-189
4.5.1.3 Securing the load for flat rack container . . . . . . . . . . . . . . . . . . . . 4-191
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4.5.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192

4.5.3 Symbols on the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192
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4.5.4 Additional notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194

5 Installation 5-195
5.1 Safety precautions during installation . . . . . . . . . . . . . . . . . . . . . 5-196
5.3 Foundation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
5.4 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
5.5 Inspecting scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
5.6 Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
8 Table of Contents
5.7 Installing and aligning the machine . . . . . . . . . . . . . . . . . . . . . . 5-200

5.7.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
5.7.2 Position of the transport locks . . . . . . . . . . . . . . . . . . . . . . . . 5-201
5.7.3 Installing and aligning the clamping unit . . . . . . . . . . . . . . . . . . . 5-202
5.7.4 Vertical alignment of the fixed mold clamping platen . . . . . . . . . . . . . 5-204
5.7.5 Install horizontal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-206
5.7.6 Fitting on protective housing . . . . . . . . . . . . . . . . . . . . . . . . . 5-207
5.7.7 Installing and aligning clamping unit . . . . . . . . . . . . . . . . . . . . . 5-212
5.8 Connection of cooling water . . . . . . . . . . . . . . . . . . . . . . . . . 5-214
5.9 Electrical connection of master switch . . . . . . . . . . . . . . . . . . . . 5-215
5.10 Replenishing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-217
5.10.1 Venting the pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-218
5.10.2 Replenishing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-219
5.11 Fill the pressure accumulator with nitrogen . . . . . . . . . . . . . . . . . . 5-221
6 Operating/display elements 6-225
6.1 Operating pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-226
6.2 Operating/display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-227
6.3 Screen operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6-231
6.3.1 Basic functions in the screen border of the operating/display panel . . . . . 6-231
6.3.1.1 Header bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-231
6.3.1.2 Actual-value column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-234
6.3.1.3 Favourites column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235
6.3.1.4 Information field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235
6.3.1.5 Main navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
6.3.2 Display objects/presentation forms on the screen . . . . . . . . . . . . . . 6-239
6.3.2.1 Fields for set value, actual value and notes . . . . . . . . . . . . . . . . . 6-239
6.3.2.2 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
6.3.2.3 Selection elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
6.3.2.4 Navigation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241
6.3.2.5 Filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241
6.3.2.6 Pop-up operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6-242
6.3.2.7 Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-243
6.3.2.8 Modifiable displays (multi-select feature) . . . . . . . . . . . . . . . . . . . 6-244
6.3.2.9 Pop-up menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244
6.3.3 Value and text input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246
6.3.3.1 Numeric keypad, value input . . . . . . . . . . . . . . . . . . . . . . . . . 6-246
6.3.3.2 Alphanumeric keypad, text input . . . . . . . . . . . . . . . . . . . . . . . 6-248
6.3.4 Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-250
MX_MC6_V1.9_07.09.15_ENG
6.3.4.1 Inserting/deleting profile stages . . . . . . . . . . . . . . . . . . . . . . . 6-251

6.3.4.2 Changing profile stages . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-251
©KM
6.3.4.3 Block changes for the barrel and mold temperatures . . . . . . . . . . . . 6-252
6.3.5 Operation of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
6.3.5.1 Alarm functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
6.3.5.2 Switch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
6.3.5.3 Activation/Acknowledgement of core-pulling setting . . . . . . . . . . . . . 6-254
6.3.6 Screen mode types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255
6.3.6.1 Keylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255
6.3.6.2 Split-screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-258
6.3.7 Configuration of screen (24" Multitouch) . . . . . . . . . . . . . . . . . . . 6-260
Table of Contents 9
6.3.8 Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-263

6.3.9 Robot operating screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-264
6.3.10 Colour scheme of display fields and buttons . . . . . . . . . . . . . . . . . . 6-265
6.3.10.1 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-265
6.3.10.2 Cycle steps/nodes in the process designer . . . . . . . . . . . . . . . . . . 6-265
6.3.10.3 Machine function buttons and mode buttons . . . . . . . . . . . . . . . . . 6-266
6.3.10.4 Machine operating buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-267
6.4 Machine function module . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-268
6.5 Operating mode buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270
6.5.1 Mode buttons for the injection molding machine . . . . . . . . . . . . . . . . 6-270
6.5.1.1 Setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270
6.5.1.2 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271
6.5.1.3 Semi-automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271
6.5.1.4 Fully automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271
6.5.1.5 Stop button (zero operating mode) . . . . . . . . . . . . . . . . . . . . . . 6-271
6.5.2 Mode buttons for robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-272
6.6 Machine operating buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-273
6.6.1 Open/close safety gate (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-274
6.6.1.1 Open safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-274
6.6.1.2 Close safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-274
6.6.2 Ejector back/forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-275
6.6.3 Mold opening/closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276
6.6.3.1 Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276
6.6.3.2 Mold closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-277
6.6.4 Moving pressure pistons back/forward, releasing/building up clamping
pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278
6.6.4.1 Moving back pressure pistons, releasing clamping pressure . . . . . . . . . 6-278
6.6.4.2 Move pressure pistons forward, build up clamping pressure . . . . . . . . . 6-278
6.6.5 Moving locking elements out/in . . . . . . . . . . . . . . . . . . . . . . . . 6-279
6.6.5.1 Moving out locking elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6-279
6.6.5.2 Move in locking elements . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-279
6.6.6 Injection unit forward/back . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-280
6.6.6.1 Injection unit forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-280
6.6.6.2 Injection unit back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-281
6.6.7 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-282
6.6.8 Screw decompression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-283
6.6.9 Plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-284
6.6.10 Locking bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-285
6.6.11 Pneumatic valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-285
MX_MC6_V1.9_07.09.15_ENG
6.6.12 Mold nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-285

6.6.13 Starting/stopping machine cycle . . . . . . . . . . . . . . . . . . . . . . . . 6-286
©KM
6.6.13.1 Starting machine cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286

6.6.13.2 Stopping machine cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287
6.6.14 Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287
6.6.14.1 Skinform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287
6.7 Slider control "SlideX" (24″ Multitouch) . . . . . . . . . . . . . . . . . . . . 6-288
6.8 Function buttons for additional components . . . . . . . . . . . . . . . . . . 6-291
6.9 Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-292
6.9.1 Core-pulling module (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-292
6.9.2 Mold change/clamping assembly module . . . . . . . . . . . . . . . . . . . 6-294
10 Table of Contents
7 Commissioning 7-297
7.1 Safety precautions for commissioning . . . . . . . . . . . . . . . . . . . . 7-298
7.2 Requirements regarding personnel operating the machine . . . . . . . . . 7-299
7.3 Cleaning of machine prior to commissioning . . . . . . . . . . . . . . . . . 7-299
7.4 Electric screw drive, inspecting oil level . . . . . . . . . . . . . . . . . . . 7-299
7.5 Inspecting central lubrication system . . . . . . . . . . . . . . . . . . . . . 7-300
7.6 Switching on/off, injection molding machine . . . . . . . . . . . . . . . . . 7-301
7.6.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301
7.6.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301
7.7 Grant/revoke input authorization . . . . . . . . . . . . . . . . . . . . . . . 7-302
7.7.1 Granting input authorization . . . . . . . . . . . . . . . . . . . . . . . . . 7-302
7.7.2 Revoking input authorization . . . . . . . . . . . . . . . . . . . . . . . . . 7-303
7.8 Switching machine components on/off . . . . . . . . . . . . . . . . . . . . 7-303
7.9 Inspecting direction of running of pump motor . . . . . . . . . . . . . . . . 7-304
7.10 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . 7-306
7.10.1 Bleed points of the hydraulic system . . . . . . . . . . . . . . . . . . . . . 7-307
7.10.2 Block pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-308
7.10.2.1 Bleeding the pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-309
7.10.2.2 Venting the pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-309
7.10.2.3 Bleeding the hydraulic pumps with asynchronous motor . . . . . . . . . . . 7-310
7.10.3 Venting the intake area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-311
7.10.3.1 Venting Bleeding the intake filter . . . . . . . . . . . . . . . . . . . . . . . 7-311
7.10.4 Venting at the pump control . . . . . . . . . . . . . . . . . . . . . . . . . 7-312
7.10.5 Venting the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . 7-313
7.10.6 Bleeding the clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314
7.10.6.1 Bleeding the pressure plunger and positioning cylinders . . . . . . . . . . . 7-314
7.10.6.2 Bleeding the locking mechanisms . . . . . . . . . . . . . . . . . . . . . . 7-315
7.10.6.3 Bleeding the MP traverse cylinder . . . . . . . . . . . . . . . . . . . . . . 7-317
7.10.7 Bleeding the injection barrel . . . . . . . . . . . . . . . . . . . . . . . . . 7-319
7.11 Inspect pump running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-321
7.12 Checking the alignment of the machine . . . . . . . . . . . . . . . . . . . 7-323
7.13 Installation of screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . 7-324
7.13.1 Notes on installation of screw barrel . . . . . . . . . . . . . . . . . . . . . 7-324
7.13.2 Installation of screw barrel SP 4300 to SP 24500 . . . . . . . . . . . . . . 7-327
7.13.2.1 Installation of screw barrel SP 4300 . . . . . . . . . . . . . . . . . . . . . 7-327
7.13.2.2 Installation of screw barrel SP 6100 to SP 24500 . . . . . . . . . . . . . . 7-329
7.13.2.3 Supporting the screw barrel SP 4300 to SP 24500 . . . . . . . . . . . . . . 7-331
7.13.2.4 Coupling the screw to SP 4300 . . . . . . . . . . . . . . . . . . . . . . . . 7-335
MX_MC6_V1.9_07.09.15_ENG
7.13.3 Installation of screw barrel SP 33000 to SP 75000 . . . . . . . . . . . . . . 7-337

7.13.3.1 Installation of screw barrel SP 33000 to SP 75000 . . . . . . . . . . . . . . 7-337
©KM
7.13.3.2 Supporting the screw barrel SP 33000 to SP 75000 . . . . . . . . . . . . . 7-338

7.13.3.3 Checking and setting screw barrel parallelism to the SP 33000 to SP 75000
injection unit machine bed . . . . . . . . . . . . . . . . . . . . . . . . . . 7-341
7.13.3.4 Coupling the screw SP 33000 to SP 75000 . . . . . . . . . . . . . . . . . 7-342
7.14 Centring nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-343
7.15 Check the nozzle insertion depth . . . . . . . . . . . . . . . . . . . . . . . 7-347
7.16 Mold installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-348
7.17 Zero point calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-351
7.17.1 Information on zero point calibration . . . . . . . . . . . . . . . . . . . . . 7-351
Table of Contents 11
7.17.2 Setting position transducer zero points . . . . . . . . . . . . . . . . . . . . 7-352

7.17.2.1 Hydraulic ejector calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 7-353
7.17.2.2 Calibration of clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . . 7-353
7.17.2.3 Calibration of injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-354
7.17.2.4 Calibration of mold venting (ZE) . . . . . . . . . . . . . . . . . . . . . . . . 7-354
7.17.2.5 Completion of calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-354
7.18 Starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-355
8 Operation of Machine 8-357
8.1 Safety precautions for operation . . . . . . . . . . . . . . . . . . . . . . . . 8-358
8.3 User login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-360
8.3.1 User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362
8.3.1.1 Creating new user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-364
8.3.1.2 Editing existing users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-367
8.3.1.3 Deleting existing user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-367
8.3.1.4 Creating a new key group . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-368
8.3.1.5 Editing existing key group . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-371
8.3.1.6 Deleting existing key group . . . . . . . . . . . . . . . . . . . . . . . . . . 8-371
8.3.2 Access rights to screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-372
8.3.3 Login settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-374
8.3.4 Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-376
8.3.4.1 Users in key groups 1 to 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-376
8.3.4.2 Users from key group 4 onwards . . . . . . . . . . . . . . . . . . . . . . . 8-377
8.3.5 Units - setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-378
8.4 Menu functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-380
8.4.1 Switch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-381
8.4.2 Create hard copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-383
8.4.2.1 System settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-384
8.4.2.2 Printer setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-385
8.4.2.3 Screen output of hard copy . . . . . . . . . . . . . . . . . . . . . . . . . . 8-386
8.4.2.4 Hard copy for pop-up window . . . . . . . . . . . . . . . . . . . . . . . . . 8-387
8.4.3 Data record loading/saving . . . . . . . . . . . . . . . . . . . . . . . . . . 8-388
8.4.4 Screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-391
8.4.5 Diagnostic files, copying onto USB stick . . . . . . . . . . . . . . . . . . . . 8-392
8.4.6 Display calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-393
8.4.7 System settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-395
8.4.8 Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-396
8.5 Help menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-397
MX_MC6_V1.9_07.09.15_ENG
8.5.1 Displaying a PDF document . . . . . . . . . . . . . . . . . . . . . . . . . . 8-398

8.5.2 Symbol explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-400
©KM
8.5.3 Alarm information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-401

8.6 Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-402
8.6.1 Changes in the cycle sequence . . . . . . . . . . . . . . . . . . . . . . . . 8-404
8.6.1.1 Change sequence of the cycle steps . . . . . . . . . . . . . . . . . . . . . 8-405
8.6.1.2 Change settings and parameters of individual cycle steps . . . . . . . . . . 8-405
8.6.1.3 Insert a new cycle step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-406
8.6.2 Wait function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-407
8.6.2.1 Basic principles of the function . . . . . . . . . . . . . . . . . . . . . . . . . 8-407
8.6.2.2 Wait categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-408
8.6.3 Cycle example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-412

8.7 Mold/Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-413
8.7.1 Mold closing/Mold safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-413
8.7.1.1 Mold closing/Mold safety with limit value profile . . . . . . . . . . . . . . . 8-413
8.7.1.2 Mold safety alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-416
8.7.1.3 Mold closing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-417
8.7.1.4 Mold closing auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . 8-419
8.7.1.5 Mold cavity pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-423
8.7.1.6 Mold set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-425
8.7.2 Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-426
8.7.2.1 Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-426
8.7.2.2 Mold opening settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-429
8.7.2.3 Mold opening auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . 8-430
8.7.2.4 Mold opening configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-434
8.7.3 Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-435
8.7.3.1 Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-435
8.7.3.2 Ejector settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-437
8.7.3.3 Ejector controlled by core-pulling program . . . . . . . . . . . . . . . . . . 8-440
8.7.3.4 Ending semi/fully automatic mode without ejector . . . . . . . . . . . . . . 8-441
8.7.3.5 Ejector configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-442
8.7.3.6 Ejector set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-443
8.7.3.7 Sprue compression and removal with ejector (ZE 71.05) . . . . . . . . . . 8-444
8.7.4 Pneumatic valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-446
8.7.4.1 Symbol explanation for pneumatic valves . . . . . . . . . . . . . . . . . . 8-449
8.7.5 Compression molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-451
8.8 Core-pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-452
8.8.1 Core-pulling activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-453
8.8.2 Interruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-455
8.8.2.1 Symbols of interruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-457
8.8.2.2 Core monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-458
8.8.3 Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-459
8.8.4 Core enabling via operating panel without sequence . . . . . . . . . . . . 8-460
8.8.5 Core-pulling settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-461
8.8.5.1 Core-pulling default settings 1 . . . . . . . . . . . . . . . . . . . . . . . . 8-461
8.8.5.2 Core-pulling default settings 2 . . . . . . . . . . . . . . . . . . . . . . . . 8-463
8.8.6 Core-pulling configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-465
8.8.7 Core-pulling programming . . . . . . . . . . . . . . . . . . . . . . . . . . 8-467
8.8.7.1 Interruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-469
8.8.7.2 Inserting/deleting core step . . . . . . . . . . . . . . . . . . . . . . . . . . 8-472
MX_MC6_V1.9_07.09.15_ENG
8.8.7.3 Core-step programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-475

8.8.7.4 Moving cores at Mold closing/opening . . . . . . . . . . . . . . . . . . . . 8-478
©KM
8.8.7.5 Symbols for core step programming . . . . . . . . . . . . . . . . . . . . . 8-479

8.9 Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-481
8.9.1 Holding pressure – injection . . . . . . . . . . . . . . . . . . . . . . . . . 8-481
8.9.1.1 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-481
8.9.1.2 Holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-485
8.9.1.3 Injection/holding pressure auxiliary devices . . . . . . . . . . . . . . . . . 8-490
8.9.1.4 Injector set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-494
8.9.2 Plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-495
8.9.2.1 Plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-495
8.9.2.2 Plasticizing configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-499

8.9.2.3 Plasticizing auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . 8-500
8.9.3 Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-502
8.9.3.1 Injection unit movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-502
8.9.3.2 Injection unit auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . 8-505
8.9.3.3 Injection unit set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . 8-507
8.9.4 Start-up/lowering, purging control . . . . . . . . . . . . . . . . . . . . . . . 8-509
8.9.4.1 Start-up/lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-509
8.9.4.2 Purging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-512
8.9.5 Cascade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-514
8.9.5.1 Nozzle cascade control (injection) . . . . . . . . . . . . . . . . . . . . . . . 8-515
8.9.5.2 Nozzle cascade control (holding pressure) . . . . . . . . . . . . . . . . . . 8-516
8.9.5.3 Cascades configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-517
8.9.5.4 Functions and parameters of the cascade control . . . . . . . . . . . . . . . 8-518
8.9.5.5 Cascade control symbol explanation . . . . . . . . . . . . . . . . . . . . . 8-519
8.9.6 Adaptive Process Control - injection/holding pressure . . . . . . . . . . . . . 8-520
8.9.6.1 Batch change control (ZE 89.528) . . . . . . . . . . . . . . . . . . . . . . . 8-520
8.9.6.2 Adaptive Process Control (ZE 89.529) . . . . . . . . . . . . . . . . . . . . . 8-525
8.10 Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-531
8.10.1 Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-531
8.10.1.1 Melt temperature (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-537
8.10.1.2 Barrel temperatures pre-settings . . . . . . . . . . . . . . . . . . . . . . . . 8-538
8.10.2 Approaching/Lowering barrel temperatures . . . . . . . . . . . . . . . . . . 8-542
8.10.2.1 System tolerances, barrel heating . . . . . . . . . . . . . . . . . . . . . . . 8-545
8.10.3 Barrel temperatures control parameters . . . . . . . . . . . . . . . . . . . . 8-546
8.10.3.1 Symbol explanations for temperature status and fault messages . . . . . . . 8-547
8.10.3.2 Barrel heating optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-548
8.10.4 Barrel heating circuit monitoring (ZE 89.3801) . . . . . . . . . . . . . . . . . 8-550
8.10.5 7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-553
8.11 Mold temperatures (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-554
8.11.1 Mold temperatures graphic . . . . . . . . . . . . . . . . . . . . . . . . . . 8-554
8.11.1.1 Symbol explanations for temperature status and fault messages . . . . . . . 8-557
8.11.1.2 Mold wall temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-558
8.11.2 Mold-temperatures start-up/lowering . . . . . . . . . . . . . . . . . . . . . 8-559
8.11.2.1 System tolerances mold heating . . . . . . . . . . . . . . . . . . . . . . . . 8-562
8.11.3 Mold temperatures control parameters . . . . . . . . . . . . . . . . . . . . 8-563
8.11.3.1 Mold heating optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-566
8.11.4 Mold heating circuit monitoring . . . . . . . . . . . . . . . . . . . . . . . . 8-568
8.11.4.1 Mold heating circuit monitoring (ZE 89.385) . . . . . . . . . . . . . . . . . . 8-568
MX_MC6_V1.9_07.09.15_ENG
8.11.4.2 Symbol legend for heating circuit monitoring status and fault messages . . . 8-570
8.11.4.3 Monitoring mold heating circuit (ZE 89.3852) . . . . . . . . . . . . . . . . . 8-571
©KM
8.11.5 Water manifolds (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-572

8.11.5.1 Water batteries FP and MP . . . . . . . . . . . . . . . . . . . . . . . . . . 8-572
8.11.5.2 Symbol legend for water manifold mode . . . . . . . . . . . . . . . . . . . . 8-574
8.11.5.3 Water manifolds, settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-576
8.11.6 External heat-balancing units (ZE) . . . . . . . . . . . . . . . . . . . . . . . 8-577
8.11.6.1 Switch on the heat-balancing unit . . . . . . . . . . . . . . . . . . . . . . . 8-578
8.11.6.2 Switch off the heat-balancing unit . . . . . . . . . . . . . . . . . . . . . . . 8-578
8.11.6.3 Evacuating heat-balancing medium (mold evacuation) . . . . . . . . . . . . 8-578
8.11.6.4 Idling mode/temperature lowering mode . . . . . . . . . . . . . . . . . . . . 8-579
8.11.6.5 Optimizing external heat-balancing units . . . . . . . . . . . . . . . . . . . 8-579
8.11.6.6 Symbol explanations for temperature status and fault messages . . . . . . 8-580
8.11.6.7 Mold temperature controllers lowering . . . . . . . . . . . . . . . . . . . . 8-581
8.11.6.8 System tolerances, heat-balancing . . . . . . . . . . . . . . . . . . . . . . 8-582
8.11.7 7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-583
8.12 Tolerance monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-584
8.12.1 Actual-value cycles and quality monitoring . . . . . . . . . . . . . . . . . . 8-584
8.12.1.1 Actual-value cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-584
8.12.1.2 Quality monitoring failure rate . . . . . . . . . . . . . . . . . . . . . . . . 8-587
8.12.1.3 Actual values exporting/printing . . . . . . . . . . . . . . . . . . . . . . . 8-588
8.12.2 Trend graph (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-589
8.12.3 Curve computer (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-591
8.12.3.1 Functions and parameters of the curve screens . . . . . . . . . . . . . . . 8-592
8.12.3.2 General functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-593
8.12.3.3 Graphic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-594
8.12.3.4 Procedure during area selection for graphic functions . . . . . . . . . . . . 8-595
8.12.3.5 Curve configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-596
8.12.3.6 Freely assignable curve screens . . . . . . . . . . . . . . . . . . . . . . . 8-598
8.12.3.7 Curve selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-599
8.13 Cycle/Times overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600
8.13.1 Overview of times and machine . . . . . . . . . . . . . . . . . . . . . . . 8-600
8.13.1.1 Overview of times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600
8.13.1.2 Machine-overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-604
8.13.2 Pieces/Shift counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-605
8.13.2.1 Pieces counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-605
8.13.2.2 Shift counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-607
8.13.2.3 EUROMAP 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-608
8.13.3 Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-610
8.13.3.1 Energy analysis (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-610
8.13.3.2 Energy balance - individual evaluation (ZE 89.77, BluePower) . . . . . . . 8-612
8.13.3.3 Energy balance - reference (ZE 89.77, BluePower) . . . . . . . . . . . . . 8-613
8.13.3.4 Energy logging DEE021 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-615
8.13.3.5 Energy logging, drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-616
8.13.3.6 Energy logging, peripherals and heaters . . . . . . . . . . . . . . . . . . . 8-617
8.13.4 Cycle settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-618
8.13.5 Eco assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-620
8.13.5.1 Optimization parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-621
8.13.5.2 Symbol explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-622
8.13.5.3 Performing optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-622
8.13.5.4 Adoption of optimized parameters . . . . . . . . . . . . . . . . . . . . . . 8-625
MX_MC6_V1.9_07.09.15_ENG
8.13.6 Machine/production status . . . . . . . . . . . . . . . . . . . . . . . . . . 8-626

8.14 Machine preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-628
©KM
8.14.1 Machine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-628

8.14.2 Mold coding (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-629
8.14.3 Screw coding (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-631
8.14.4 Production data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-633
8.14.4.1 Set-up and production data 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8-633
8.14.4.4 Production set data 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-636
8.14.4.5 Production set data 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-637
8.14.4.6 Production data, mold temperatures . . . . . . . . . . . . . . . . . . . . . . 8-638

8.14.5 7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-639
8.14.5.1 7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-639
8.14.5.2 Control 7-day timer via start of production . . . . . . . . . . . . . . . . . . . 8-641
8.15 Peripherals (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-643
8.15.1 Inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-643
8.15.1.1 Freely programmable inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 8-643
8.15.1.2 Freely programmable outputs . . . . . . . . . . . . . . . . . . . . . . . . . 8-644
8.15.2 Production signals BDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-645
8.15.3 Production signals CIMI (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . 8-646
8.15.4 Interface EUROMAP 67 (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . 8-647
8.15.5 External alarm inputs (ZE 89.9696) . . . . . . . . . . . . . . . . . . . . . . 8-648
8.15.6 Displaying image of a camera . . . . . . . . . . . . . . . . . . . . . . . . . 8-651
8.15.7 Scales (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-652
8.15.8 Laminar flow box (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-653
8.16 Configuration/Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-654
8.16.1 Service and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-654
8.16.1.1 KM Service (KraussMaffei Service) . . . . . . . . . . . . . . . . . . . . . . 8-654
8.16.1.2 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-655
8.16.1.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-658
8.16.1.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-659
8.16.2 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-660
8.16.2.1 Diagnosis, injection molding machine . . . . . . . . . . . . . . . . . . . . . 8-660
8.16.2.2 Robot diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-665
8.16.3 Step display diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-666
8.16.4 Diagnosis, servo pumps and electric screw drive . . . . . . . . . . . . . . . 8-667
8.16.4.1 Settings/diagnosis, converter 1 . . . . . . . . . . . . . . . . . . . . . . . . 8-667
8.16.4.2 Settings/diagnosis, converter 2 . . . . . . . . . . . . . . . . . . . . . . . . 8-669
8.16.4.3 Diagnosis of electric screw drive . . . . . . . . . . . . . . . . . . . . . . . . 8-670
8.16.5 System pressures, hydraulic pressure transducer . . . . . . . . . . . . . . . 8-671
8.17 Alarms/Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-672
8.17.1 Alarm overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-672
8.17.2 Settings alarm overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-674
8.17.3 Events log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-675
8.17.3.1 Symbol legend for events log . . . . . . . . . . . . . . . . . . . . . . . . . 8-677
8.17.3.2 Events log exporting/printing . . . . . . . . . . . . . . . . . . . . . . . . . . 8-678
8.17.4 Overview of machine doors . . . . . . . . . . . . . . . . . . . . . . . . . . 8-679
8.18 Notebook (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-681
8.18.1 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-682
MX_MC6_V1.9_07.09.15_ENG
8.18.1.1 Creating and renaming categories and notes . . . . . . . . . . . . . . . . . 8-684

8.18.1.2 Linking a note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-688
©KM
8.18.1.3 Exporting note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-688

8.18.2 Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-689
8.18.2.1 Text operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-690
8.18.2.2 Writing operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-691
8.18.2.3 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-692
8.18.2.4 Text marking aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-694
8.18.3 Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-694
8.18.4 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-695

8.18.4.1 Opening attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-695
8.18.4.2 Selection of note when opening the notebook . . . . . . . . . . . . . . . . 8-695
9 Rectifying Faults 9-697
10 Maintenance 10-699
10.1 Maintenance agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-700
10.2 Safety precautions for maintenance and repair . . . . . . . . . . . . . . . 10-700
10.3 Requirements regarding personnel operating the machine . . . . . . . . . 10-703
10.4 General maintenance instructions . . . . . . . . . . . . . . . . . . . . . . 10-703
10.5 Maintenance scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-704
10.6 Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-707
10.7 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-707
10.8 Lubrication/oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-708
10.8.1 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 10-709
10.8.2 Injection unit lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-711
10.8.2.1 Lubricating injection plunger guides from SP 6100 . . . . . . . . . . . . . . 10-712
10.8.2.2 Support for screw barrel, lubricating . . . . . . . . . . . . . . . . . . . . . 10-713
10.8.2.3 Lubricating the piston rod bearings from SP 2000 . . . . . . . . . . . . . . 10-714
10.8.2.4 Lubricate the profile rail guides . . . . . . . . . . . . . . . . . . . . . . . . 10-715
10.8.3 Actuation cylinder joint for the nozzle pintle shut-off . . . . . . . . . . . . . 10-717
10.8.4 Electric screw drive (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-718
10.8.4.1 Spur flat gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-718
10.8.4.2 CMG gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-719
10.8.4.3 Changing oil, electric screw drive . . . . . . . . . . . . . . . . . . . . . . . 10-721
10.9 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-723
10.9.1 Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-723
10.9.2 Changing hydraulic oil/cleaning hydraulic oil tank . . . . . . . . . . . . . . 10-724
10.9.2.1 Tank return-flow shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . 10-725
10.9.2.2 Cleaning hydraulic oil tank, changing hydraulic oil . . . . . . . . . . . . . . 10-726
10.9.2.3 Inspect oil level of hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . 10-727
10.9.2.4 Replenishing oil in the hydraulic oil tank . . . . . . . . . . . . . . . . . . . 10-727
10.9.3 Pump motor oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-728
10.9.4 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-730
10.9.4.1 Cleaning water-bearing parts . . . . . . . . . . . . . . . . . . . . . . . . . 10-730
10.9.4.2 Cleaning oil-bearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . 10-730
10.9.5 Cleaning intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-733
10.9.6 Fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-735
10.9.6.1 Replacing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-735
MX_MC6_V1.9_07.09.15_ENG
10.9.7 Return-flow filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-737

©KM
10.9.7.1 Replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-737

10.9.8 Internal bypass flow filter, replacing filter element (ZE 63.65) . . . . . . . . 10-739
10.9.9 Air admission and release filter, clean/replace filter element . . . . . . . . . 10-741
10.10 Cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-743
10.10.1 Hydraulic oil cooling/Barrel flange cooling . . . . . . . . . . . . . . . . . . 10-743
10.10.1.1 Inspect the function of the barrel flange cooling . . . . . . . . . . . . . . . 10-744
10.10.2 Mold cooling (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-745
10.10.3 Water filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-745
10.11 Compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-746
10.11.1 Maintenance unit (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-746
10.12 Plasticizing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-748

10.12.1 Dangers when working on heated plasticizing units . . . . . . . . . . . . . 10-748
10.12.2 Checking and setting the screw barrel support . . . . . . . . . . . . . . . 10-749
10.12.2.1 Checking and setting the support for SP 4300 to SP 24500 . . . . . . . . . 10-749
10.12.2.2 Checking and setting the support for SP 33000 to SP 75000 . . . . . . . . 10-751
10.12.2.3 Checking and setting screw barrel parallelism to the SP 33000 to SP 75000
injection unit machine bed . . . . . . . . . . . . . . . . . . . . . . . . . . 10-752
10.12.3 Screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-753
10.12.3.1 Cleaning the nozzle and the injection area . . . . . . . . . . . . . . . . . 10-753
10.12.3.2 Purging screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-754
10.12.3.3 Replacing the screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-755
10.12.3.4 Cleaning the screw barrel after removing . . . . . . . . . . . . . . . . . . 10-760
10.12.4 Inspecting the firm fitting of screw coupling . . . . . . . . . . . . . . . . . 10-761
10.12.5 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-762
10.12.5.1 Cleaning screw with cleaning material . . . . . . . . . . . . . . . . . . . . 10-762
10.12.5.2 Cleaning the screw after removing . . . . . . . . . . . . . . . . . . . . . . 10-763
10.12.6 Nozzle and barrel head . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-764
10.12.6.1 Removing/installing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 10-765
10.12.6.2 Barrel head connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-766
10.12.6.3 Removing/installing the barrel head . . . . . . . . . . . . . . . . . . . . . 10-766
10.12.7 Return-flow lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-768
10.12.7.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-768
10.12.7.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-768
10.12.7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-770
10.12.8 Ball return-flow lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-771
10.12.8.1 Assembly of ball return-flow lock . . . . . . . . . . . . . . . . . . . . . . . 10-771
10.12.9 Central ball - return-flow lock (SP 4300 MX to SP 24500 MX) . . . . . . . . 10-772
10.12.10 Screw barrel nozzle shut-off . . . . . . . . . . . . . . . . . . . . . . . . . 10-774
10.12.10.1 Checking and adjust pintle catch . . . . . . . . . . . . . . . . . . . . . . 10-774
10.12.11 Heating bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-776
10.12.11.1 Removing heating bands . . . . . . . . . . . . . . . . . . . . . . . . . . 10-776
10.12.11.2 Installing heating bands . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-777
10.13 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-778
10.13.1 Cleaning/replacing the filter mats in the fan . . . . . . . . . . . . . . . . . 10-778
10.14 Changing the backup battery . . . . . . . . . . . . . . . . . . . . . . . . 10-779
10.14.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-779
10.14.2 Battery change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-780
10.15 Replacing protective film on touchscreen . . . . . . . . . . . . . . . . . . 10-783
10.16 Changing pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . 10-784
MX_MC6_V1.9_07.09.15_ENG
10.16.1 Drain the nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-784

10.16.2 Removing the pressure accumulator . . . . . . . . . . . . . . . . . . . . 10-786
©KM
10.16.3 Installing the pressure accumulator . . . . . . . . . . . . . . . . . . . . . 10-787

10.16.4 Fill the pressure accumulator with nitrogen . . . . . . . . . . . . . . . . . 10-787
10.16.5 Check pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . 10-787
10.16.5.1 Fill pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-787
10.16.5.2 Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-788
11 Peripherals / Interfaces 11-789
11.1 Description of interface, parts removal unit (ZE 89.5901⁄ZE 89.5902) . . . . 11-790
11.1.1 Interface map for plug-in connection (-XY100A) . . . . . . . . . . . . . . . 11-790
11.1.2 Contact assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-790
11.1.3 Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-791

11.1.4 Description of signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-792
11.1.4.1 Injection molding machine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-792
11.1.4.2 Parts removal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-793
11.1.5 Contact type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-795
11.1.6 Contact specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-795
11.1.7 Ejector with robot synchronization . . . . . . . . . . . . . . . . . . . . . . 11-795
11.2 Interface EUROMAP 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-796
11.2.1 Contact type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-796
11.2.2 Plug connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-796
11.2.4 Contact specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-798
11.2.5 Interface Euromap 73 and lateral removal (ZE) . . . . . . . . . . . . . . . 11-799
11.2.5.1 Lateral demolding, operator rearside (ZE 89.5924⁄5921) . . . . . . . . . . . 11-799
11.2.5.2 Later demolding, operator side (ZE 89.5925⁄5922) . . . . . . . . . . . . . . 11-799
11.3 Description of interface, hot runner system . . . . . . . . . . . . . . . . . . 11-800
11.3.1 Interface map for plug-in connection (-XJ701 to -XJ7xx / -XT701 to -XT7xx) 11-800
11.3.2 Contact assignment, heating elements . . . . . . . . . . . . . . . . . . . . 11-800
11.3.3 Contact assignment, thermo sensors . . . . . . . . . . . . . . . . . . . . . 11-801
11.4 Description of interface, heat-balancing units via control system
(ZE 88.56xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-802
11.4.1 Interface map for plug-in connection (-XJ801 to -XJ8xx) . . . . . . . . . . . 11-802
11.4.3 Contact type, power rating . . . . . . . . . . . . . . . . . . . . . . . . . . 11-802
11.5 Description of interface, heat-balancing units 20 mA (ZE 89.965) . . . . . . 11-803
11.5.1 Plug-in connection (-XYV24T) . . . . . . . . . . . . . . . . . . . . . . . . 11-803
11.6 Description of interface, production data acquisition (BDE) . . . . . . . . . 11-805
11.6.1 Interface map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-805
11.7 Description of interface, cascade control . . . . . . . . . . . . . . . . . . . 11-806
11.7.1 Design of the sensor-actuator box . . . . . . . . . . . . . . . . . . . . . . 11-806
11.7.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-807
11.8 Terminal assignment, touchscreen operating panel . . . . . . . . . . . . . 11-808
11.8.1 Interface on front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-808
11.8.2 Interfaces on rearside . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-809
11.9 Interfaces, control cabinet PC . . . . . . . . . . . . . . . . . . . . . . . . 11-811
11.9.1 PC 322-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811
MX_MC6_V1.9_07.09.15_ENG
11.9.1.1 Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811

11.9.1.2 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-812
©KM
11.9.1.3 USB memory expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-813

11.9.2 Signal extender plug-in module . . . . . . . . . . . . . . . . . . . . . . . . 11-814
11.9.2.1 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-814
11.10 Interface, laminar flow box (ZE) . . . . . . . . . . . . . . . . . . . . . . . 11-815
11.10.1 Status of laminar flow box . . . . . . . . . . . . . . . . . . . . . . . . . . 11-816
11.10.1.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-816
11.10.1.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-816
11.10.1.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-817
11.10.1.4 Step display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-817
12 Auxiliary devices 12-819

12.1 Material hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-820
12.1.1 Attaching material hopper . . . . . . . . . . . . . . . . . . . . . . . . . . 12-820
12.1.2 Ladder (ZE 12.90) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-822
12.1.2.1 Use of the ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-822
12.1.2.2 Height compensation for ladder . . . . . . . . . . . . . . . . . . . . . . . 12-823
12.1.2.3 Support for ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-824
12.1.2.4 Folding joint of ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-824
12.2 Chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-825
12.2.1 Control system-dependent user login . . . . . . . . . . . . . . . . . . . . 12-826
12.2.2 Input authorization with chip card . . . . . . . . . . . . . . . . . . . . . . 12-826
12.2.3 Programming the chip card . . . . . . . . . . . . . . . . . . . . . . . . . 12-828
12.2.3.1 Activating chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-828
12.2.3.2 Direct programming of the chip card (without user data from the control
system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-830
12.2.3.3 Programming user data from the control system onto the chip card . . . . . 12-832
12.2.3.4 New creation of user data on the control system with activated chip card . . 12-833
12.2.4 RFID chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-834
12.3 Quality statistics (ZE 89.6705) . . . . . . . . . . . . . . . . . . . . . . . . 12-835
12.3.1 Quality statistics overview . . . . . . . . . . . . . . . . . . . . . . . . . . 12-835
12.3.2 Configuration of control chart . . . . . . . . . . . . . . . . . . . . . . . . 12-838
12.3.2.1 Parameter selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-839
12.3.2.2 Test schedule inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-840
12.3.3 Function selection, control chart . . . . . . . . . . . . . . . . . . . . . . . 12-841
12.3.4 Configuration of test data . . . . . . . . . . . . . . . . . . . . . . . . . . 12-842
12.3.5 Quality-statistics, control chart . . . . . . . . . . . . . . . . . . . . . . . . 12-844
12.3.6 Quality-statistics history . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-847
12.3.7 Measuring line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-849
12.3.8 Process capability and stability investigation . . . . . . . . . . . . . . . . 12-850
12.4 Master computer interface EUROMAP 63/SPI (ZE 89.9485, 89.9486) . . . 12-852
12.4.1 Description of standard EUROMAP 63/SPI . . . . . . . . . . . . . . . . . 12-852
12.4.2 Contact assignment Ethernet 2 X4 . . . . . . . . . . . . . . . . . . . . . 12-852
12.4.3 File transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-853
12.4.3.1 Requirements for the master computer . . . . . . . . . . . . . . . . . . . 12-854
12.4.3.2 Requirements for the machine control system and the network . . . . . . . 12-854
12.4.4 Interface function at the machine . . . . . . . . . . . . . . . . . . . . . . 12-855
12.4.4.1 Network (network settings) . . . . . . . . . . . . . . . . . . . . . . . . . . 12-855
12.4.4.2 Euromap 63 (network settings) . . . . . . . . . . . . . . . . . . . . . . . 12-859
12.4.4.3 Configuration for teleservice (network settings) . . . . . . . . . . . . . . . 12-865
MX_MC6_V1.9_07.09.15_ENG
12.4.5 Notes for the programmer of the master computer . . . . . . . . . . . . . 12-867

12.4.5.1 Measures for safe communication . . . . . . . . . . . . . . . . . . . . . . 12-868
©KM
12.4.6 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-869

12.4.6.1 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-869
12.4.6.2 Code set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-869
12.4.6.3 File access and maintenance of the master computer . . . . . . . . . . . . 12-869
12.4.6.4 Communication faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-869
12.4.6.5 Comments on list and file names . . . . . . . . . . . . . . . . . . . . . . 12-870
12.4.7 Restrictions, special features and extensions for MC6 control systems . . . 12-870
12.4.7.1 Sequence of session file processing . . . . . . . . . . . . . . . . . . . . . 12-870
12.4.7.2 Parameter names and values . . . . . . . . . . . . . . . . . . . . . . . . 12-870
12.4.7.3 Wildcard parameter names . . . . . . . . . . . . . . . . . . . . . . . . . . 12-870

12.4.7.4 Upload and download . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-871
12.4.8 Examples of Euromap 63/SPI commands . . . . . . . . . . . . . . . . . . 12-873
12.4.8.1 Syntax session file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-873
12.4.8.2 Syntax job files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-873
12.5 Bypass flow filter, replacing the filter element (ZE 63.662) . . . . . . . . . . 12-878
12.6 Bypass flow filter from SP 24500 (ZE 63.66) . . . . . . . . . . . . . . . . . 12-880
12.6.1 Replacing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 12-881
12.7 Keyswitch (-S016) ejector/cores with open safety gate (ZE 89.08), foot
switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-882
12.7.1 Function of the keyswitch -S016 . . . . . . . . . . . . . . . . . . . . . . . 12-883
12.7.2 Function of the foot switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12-884
12.7.3 Inspecting core-pulling/ejector function with open safety gate . . . . . . . . 12-885
12.8 Water manifold (ZE 76.5xx, 76.7xx) . . . . . . . . . . . . . . . . . . . . . 12-886
12.8.1 Flow rate monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-886
12.8.2 Clean/replace flow controller . . . . . . . . . . . . . . . . . . . . . . . . . 12-887
12.9 Medium monitor (ZE 64.50) . . . . . . . . . . . . . . . . . . . . . . . . . 12-888
12.9.1 Function check of the medium monitor . . . . . . . . . . . . . . . . . . . . 12-888
12.10 Display core-pulling, ejector and mold clamping assembly . . . . . . . . . . 12-890
12.11 Automatic feed unit (ZE 12.80, 12.81) . . . . . . . . . . . . . . . . . . . . 12-893
12.11.1 Safety devices/information plates . . . . . . . . . . . . . . . . . . . . . . 12-893
12.11.1.1 Safety devices/information plates AF 50 . . . . . . . . . . . . . . . . . . . 12-894
12.11.1.2 Safety devices/information plates AF 100 . . . . . . . . . . . . . . . . . . 12-895
12.11.1.3 Functional check of limit switches . . . . . . . . . . . . . . . . . . . . . . 12-895
12.11.2 Design and function of the AF 50/100 . . . . . . . . . . . . . . . . . . . . 12-896
12.11.3 Information on mold masses . . . . . . . . . . . . . . . . . . . . . . . . . 12-898
12.11.3.1 Storage of mold masses . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-898
12.11.3.2 Mold mass delivery forms . . . . . . . . . . . . . . . . . . . . . . . . . . 12-899
12.11.4 Notes on processing BMC . . . . . . . . . . . . . . . . . . . . . . . . . . 12-899
12.11.4.1 Injection melt hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-899
12.11.4.2 Finding and rectifying faults, BMC . . . . . . . . . . . . . . . . . . . . . . 12-900
12.11.5 Commissioning AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-901
12.11.5.1 AF 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-901
12.11.5.2 AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-903
12.11.6 De-commissioning AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-904
12.11.6.1 AF 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-904
12.11.6.2 AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-904
12.11.7 Removal of the feed screw . . . . . . . . . . . . . . . . . . . . . . . . . . 12-905
12.11.7.1 AF 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-905
MX_MC6_V1.9_07.09.15_ENG
12.11.7.2 AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-906

12.11.8 Operating elements, AF . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-908
©KM
12.11.8.1 AF machine operating buttons . . . . . . . . . . . . . . . . . . . . . . . . 12-908

12.11.8.2 Hopper right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-909
12.11.8.3 Hopper left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-909
12.11.8.4 Rotate feed screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-910
12.11.9 Operation of AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-911
12.11.9.1 Activating automatic feed unit . . . . . . . . . . . . . . . . . . . . . . . . 12-911
12.11.9.2 Display/set-up of automatic feed unit . . . . . . . . . . . . . . . . . . . . . 12-912
12.11.9.3 AF Automatic feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-913
12.11.9.4 Parameters for stuffing pressure closed-loop control . . . . . . . . . . . . . 12-914
12.11.9.5 Parameters of the AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-914

12.11.9.6 Selection of hopper function . . . . . . . . . . . . . . . . . . . . . . . . . 12-915
12.11.9.7 Material monitoring parameters . . . . . . . . . . . . . . . . . . . . . . . 12-916
12.11.9.8 Parameters for torque monitoring . . . . . . . . . . . . . . . . . . . . . . 12-917
12.11.9.9 Purging program at end of production . . . . . . . . . . . . . . . . . . . . 12-918
12.11.9.10 Polylift automatic loading system . . . . . . . . . . . . . . . . . . . . . . 12-921
12.11.9.11 Duroplast conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-923
12.11.9.12 AF alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-924
12.11.9.13 Heat-balancing of AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-925
12.11.9.14 Starting the AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-925
12.11.9.15 Production interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-926
12.11.9.16 Calibration of the pressure transducer BP531 . . . . . . . . . . . . . . . . 12-927
12.11.9.17 Setting the material level display . . . . . . . . . . . . . . . . . . . . . . . 12-928
12.11.10 AF fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-929
12.11.11 Maintenance AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-930
12.11.11.1 Materials used in operation . . . . . . . . . . . . . . . . . . . . . . . . . 12-930
12.11.11.2 Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-931
12.11.11.3 Inspecting oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-932
12.11.11.4 Lubrication of material feed unit . . . . . . . . . . . . . . . . . . . . . . . 12-932
12.11.12 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-933
12.11.12.1 Emptying of AF 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-933
12.11.12.2 Emptying of AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-934
12.11.13 Cleaning of AF 50/100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-936
12.11.13.1 Cleaning with non-reactive material . . . . . . . . . . . . . . . . . . . . . 12-936
12.11.14 AF vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-937
12.11.14.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-937
12.11.14.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-938
12.11.14.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-944
12.11.14.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-944
12.11.14.5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-948
12.12 Bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-949
12.12.1 Variants of the bar-pulling device . . . . . . . . . . . . . . . . . . . . . . 12-949
12.12.1.1 Bar-pulling device with support, rear . . . . . . . . . . . . . . . . . . . . . 12-951
12.12.1.2 Bar-pulling device, self-supporting (without support) . . . . . . . . . . . . 12-952
12.12.2 Operating/display elements . . . . . . . . . . . . . . . . . . . . . . . . . 12-954
12.12.3 Moving bar out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-955
12.12.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-955
12.12.3.2 Moving bar out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-956
12.12.3.3 Moving bar in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-957
MX_MC6_V1.9_07.09.15_ENG
12.12.4 Alarms, bar-pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-958

12.12.5 Bar-pulling for mold change . . . . . . . . . . . . . . . . . . . . . . . . . 12-959
©KM
12.12.6 Venting the bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . 12-961

12.12.7 Servicing the bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . 12-962
12.12.7.1 Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-963
12.12.7.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-963
12.13 Self-sufficient gas/water systems (EUROMAP 62) . . . . . . . . . . . . . 12-964
12.13.1 Input and output signals, gas/water system . . . . . . . . . . . . . . . . . 12-965
12.13.1.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-965
12.13.1.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-966
12.14 Magnetic clamping system (ZE 45.695x, 89.57x) . . . . . . . . . . . . . . 12-968
12.14.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-968

12.14.1.1 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-969
12.14.1.2 Safety displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-969
12.14.1.3 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-970
12.14.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-971
12.14.3 Mold change with holding force display (ZE 89.573) . . . . . . . . . . . . . 12-971
12.14.3.1 Mold change interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-971
12.14.3.2 Determining holding force of the magnetic clamping system . . . . . . . . . 12-973
12.14.3.3 Status messages during mold change . . . . . . . . . . . . . . . . . . . . 12-974
12.14.3.4 Alarm messages during mold change . . . . . . . . . . . . . . . . . . . . 12-975
12.14.4 Setting machine forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-976
12.14.5 Operation / mold change . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-978
12.14.5.1 Magnetizing per operating/display panel (ZE 89.571, 89.573) . . . . . . . . 12-978
12.14.5.2 Magnetizing per operating/display panel (ZE 89.571, 89.573) . . . . . . . . 12-980
12.14.5.3 Magnetizing/demagnetizing at the magnetic clamping system (ZE 89.57) . . 12-983
12.14.6 Control panel (example ZE 89.571) . . . . . . . . . . . . . . . . . . . . . 12-984
12.14.6.1 Magnetic clamping plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-984
12.14.6.2 Control panel of magnetic clamping system . . . . . . . . . . . . . . . . . 12-985
12.14.6.3 LEDs in the control cabinet for the magnetic clamping system . . . . . . . . 12-987
12.14.7 Fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-988
12.14.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-988
12.14.9 Taking machine out of service . . . . . . . . . . . . . . . . . . . . . . . . 12-988
12.15 Mold heating KraussMaffei/PSG (ZE) . . . . . . . . . . . . . . . . . . . . 12-989
12.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-989
12.15.2 Automatic ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-989
12.15.3 Prioritized heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-990
12.15.4 Drying out program (Heat‘n‘Dry) . . . . . . . . . . . . . . . . . . . . . . . 12-991
12.15.5 Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-993
12.15.6 Guide zone mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-995
12.15.7 Hotrunner leak monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 12-997
12.15.8 Sensor type/compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 12-999
12.15.9 Heating circuit monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 12-1002
12.15.10 Diagnosis mold hotrunner system - MoldCheck . . . . . . . . . . . . . . 12-1004
12.15.10.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1006
12.15.10.2 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1009
12.16 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1011
13 Taking machine out of service/Placing into storage/Disposal 13-1013
13.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1014
13.2 Requirements regarding personnel operating the machine . . . . . . . . 13-1014
MX_MC6_V1.9_07.09.15_ENG
13.3 Shutting down the machine . . . . . . . . . . . . . . . . . . . . . . . . . 13-1015

©KM
13.4 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1016

13.5 Taking machine out of service . . . . . . . . . . . . . . . . . . . . . . . 13-1016
13.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1017
13.6.1 Information regarding disposal procedure . . . . . . . . . . . . . . . . . 13-1017
13.6.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1017
13.6.3 Disposal points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1019
14 Index 14-1021
15 Parts lists/drawings 15-1035
15.1 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1037
15.2 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1039
15.3 Foundation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1041
15.4 Mold connection dimensions . . . . . . . . . . . . . . . . . . . . . . . . 15-1043
15.5 Overview of heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1045
15.6 Overview of nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1047
15.7 Equipment-specific ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1049
16 Electrical system 16-1051
17 Hydraulics/Pneumatics 17-1053
18 Supplier Documentation 18-1055
19 Reports/Certificates 19-1057
19.1 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . 19-1057
20 Revision Record 20-1059
MX_MC6_V1.9_07.09.15_ENG
©KM
0 Preface
This chapter provides information on the purpose and structure of this document.
0.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
0.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . 27
0.3 Structure of the technical documentation . . . . . . . 28
0.4 Target group of the technical documentation . . . . 29
0.5 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
0.6 User assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
0.7 Warranty provisions . . . . . . . . . . . . . . . . . . . . . . . . . 30
0.8 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
0.9 Download order-related MC6 software and

documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
0.10 KraussMaffei addresses . . . . . . . . . . . . . . . . . . . . . . 36
0.11 Index of abbreviations . . . . . . . . . . . . . . . . . . . . . . . 44

MX_MC6_V1.9_07.09.15_ENG
©KM
Preface 0-25
0.1 Intended use
0.1.1 General
The injection molding machine is intended solely for the injection molding of
plastic articles. The injection material used are granulated thermoplastics and
pressure setting plastics, as appropriate with additives, within the specified limits.
The material filling hole at the plasticizing unit of the injection molding machine,
or the hopper sliding mechanism, is designed as the interface for operation with
an automatic conveying device that must be provided on site before the start of
production. In the case of manual material infeed, a standardized climbing aid
must be provided on site. If necessary, this can be supplied by KraussMaffei.
Any use other than this or beyond this is considered to be not in conformity with
specifications and is a misuse of the machine.
0.1.2 Machine limits and products

The limits of the injection unit with regard to the Machinery Directive and the
producible products are defined by the technical data, the foundation plan and the
provisions in section 0.1.1 "General".
0.1.3 Safety devices

The protective panelling at the injection molding machine are safety devices and
must not be removed, modified or taken out of operation if the machine is to be
used in conformity with the specifications.
Limit switches must not be bypassed or rendered ineffective.
0.1.4 User information

Use of the machine in accordance with specifications includes:
• proper compliance with all the instructions in the operating manual and
• proper compliance with the specified inspection and servicing work.
0.1.5 Electromagnetic compatibility - EMC

The injection molding machine is intended only for use in an industrial
environment. The machine must therefore not be used in a residential area, in
MX_MC6_V1.9_07.09.15_ENG
commercial and trade areas and not in small companies.

©KM
0.1.6 Improper use/Foreseeable misuse

• Injection molding of products which do not comply with the above
specifications.
• Operation of the machine in an explosive atmosphere.
• Influence of vibrations during operation.
0-26 Preface
0.2 Purpose of the document

• The technical documentation provides the owner/operator of the machine
with the information required to obtain the maximum possible efficiency.
• The primary aim is to protect persons from hazardous situations and the
machine from damage resulting from improper use.
• Regular maintenance and servicing, as specified in these operating
instructions, maintain the accuracy and operational readiness of the injection
unit throughout its entire life.
• If breakdowns or faults occur which are not within the owner/operator’s power
to rectify, please contact KraussMaffei Customer Service.
MX_MC6_V1.9_07.09.15_ENG
©KM
Preface 0-27
0.3 Structure of the technical documentation
W
Important
The operating company must ensure that the complete printed operating
instructions are available at all times to operating, maintenance and repair
personnel.
• The technical documentation contains the operating manual and technical

documents.
• The operating instructions consist of brief instructions in printed form and
complete instructions saved electronically on CD-ROM.
• The brief instructions contain all information from the complete operating
manual required for installation, commissioning and decommissioning.
• Foundation drawings and tables with the mold connection dimensions
necessary for installation and commissioning have been enclosed with the
brief instructions as technical documents.
The technical documentation is structured as follows:
Structure Chapter Brief instructions chapter

• Preface • Preface
• Safety • Safety
• Fundamentals of Injection • Specifications
Molding Technology • Transport/Packaging
• Specifications • Installation
• Transport/Packaging • Commissioning
• Installation • Taking machine out of service/
• Operating/display elements Placing into storage/Disposal
Operating • Commissioning • Index
instructions • Operation of Machine
Technical • Rectifying Faults
documentation • Maintenance
• Peripherals / Interfaces
• Auxiliary devices
• Taking machine out of service/
MX_MC6_V1.9_07.09.15_ENG
Placing into storage/Disposal

• Index
©KM
• Parts lists/drawings • Excerpts from parts lists/

Technical • Electrical system drawings
documents • Hydraulics/Pneumatics • Electrical system
• Supplier Documentation • Hydraulics/Pneumatics
• Reports/Certificates • Reports/Certificates
• Revision Record
0-28 Preface
0.4 Target group of the technical documentation
0.4.1 Operating instructions

These operating instructions are intended primarily for the operating personnel.
"Operating personnel" as defined by this operating manual is a person, or are
persons, who is (are) responsible for the installation, commissioning, operation,
maintenance including cleaning, rectification and faults and transport of the
machine.
• The machine must be operated, serviced or repaired only by trained and
authorized persons.
• The responsibilities for the individual operations at this machine must be
clearly defined and observed. From a safety aspect there may not be any
misunderstandings regarding responsibilities.
• Any person who is considered a machine operative within the user's company
must have read and understood the operating manual and in particular the
"Safety" chapter.
Storage point
W
Important
The operating manual shall always be kept at the machine and must always be
readily accessible.
0.4.2 Technical documents

The technical documents contain more extensive information.
They are an essential element of the technical documentation.
MX_MC6_V1.9_07.09.15_ENG
©KM
Preface 0-29
0.5 Service life

Repair or maintenance work is essential as the result of wear-and-tear resulting
from normal operation. KraussMaffei declines any warranty for proper operation
of the machine if such repair or maintenance work is not carried out in accordance
with our specifications. Please also refer in this connection to our warranty
provisions in the sales documents.
0.6 User assessment

Dear Reader,
Our Operating Instructions are updated regularly. With his own suggestions for
improvement, the owner/company helps us in designing operating instructions
which are even more user-friendly. Please address the training department with
information by fax, e-mail or telephone (see section 0.8, page 0-31).
0.7 Warranty provisions

• The contractual arrangements made with KraussMaffei govern
KraussMaffei’s liability and guarantees.
• It is prohibited under all circumstances to open assemblies during the
warranty period.
• Any devices or components subject to complaint must be sent to
KraussMaffei or its agents so that warranty claims can be checked.
• Replacement supplies shall be invoiced in an initial phase.
• If an authorized warranty claim exists, the corresponding credit note will be
issued without delay.
• Only authorized KraussMaffei personnel are permitted to carry out any work
on the electronics components.
MX_MC6_V1.9_07.09.15_ENG
©KM
0-30 Preface
0.8 Training
As the operating company, to provide machine operators, setters, programmers
and maintenance technicians with comprehensive specialist knowledge and to
keep them up-to-date with the latest technical status of KraussMaffei injection
molding machines, we recommend the range of seminars offered by
KraussMaffei.
Seminar focal points are:

• Know-how on injection molding machines and machine series
• Know-how on process engineering
• Increase in machine availability
• Shortening of downtimes and set-up times
• Improvement in product quality
• Targeted fault elimination
• Reduction in operating and maintenance/repair costs
For further information, the owner/company should contact our training

department. We will gladly send you our seminar program.
Address of training department
KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2
D-80997 Munich, Germany
Phone: +49 89 88 99 - 41 50
Fax: +49 89 88 99 - 16 94
MX_MC6_V1.9_07.09.15_ENG
©KM
Preface 0-31
0.9 Download order-related MC6 software and documentation

The web portal described in the following section allows you to call up machine-
specific documentation (plans and operating instructions) as well as software
(MC6).
A prerequisite for the download is an Internet connection.
I
Note
The web portal only provides the current version of the machine-specific
documentation and software.
1) Call up the web portal under the following link:

www.kraussmaffei.com/documentation
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 0.1 KraussMaffei web access

1 Download "Machine-specific documentation and software"
2) On the "Machine-specific documentation and software" page, select the link

"Machine-specific documentation and software" (1, fig. 0.1).
0-32 Preface
Fig. 0.2 Download machine-specific documentation and software (1/3)

1 "Order" input field 2 "Key" input field
3) On the "Download machine-specific documentation and software" page

(see fig. 0.2, page 0-33), enter the complete order number (1, fig. 0.2) and
the order-specific key (2).
I
Note
Every order entered after the end of 2007 receives an order-specific key. The
key is required for authentication when downloading machine-specific
documents and software. The key can be found in the files "software.doc"
(1, fig. 0.3) and 38610xxx.inf" (order number). These files are on the stick or
are printed out in the control cabinet.
MX_MC6_V1.9_07.09.15_ENG
©KM
Preface 0-33
Fig. 0.3 "software.doc" file

1 Key
1 2 3

1 "Order" input field 3 "Search" button
2 "Key" input field
I
Note
MX_MC6_V1.9_07.09.15_ENG
Observe upper and lower case when entering the key number.
©KM
4) After entering the order and key number, press the "Search" (3, fig. 0.4)
button. The search for the system-specific documents is tripped.
The search results are presented in the form of a selection list (2, fig. 0.5) in
the next screen.
0-34 Preface
1 2

1 "Download" button 2 Selection list
5) Select all relevant documents from the selection list (2, fig. 0.5) by
mouseclick. Then start the download via the "Download" (1) button.
6) The data is saved on a local drive/directory. Depending on the browser used,
a prompt appears asking whether the requested files are to be opened or
saved and where the storage location is to be.
MX_MC6_V1.9_07.09.15_ENG
©KM
Preface 0-35
0.10 KraussMaffei addresses
Country Company Contact person

Germany KraussMaffei Technologies Rühmer, Reinhardt
Vertrieb und Service Center Tel.: +49 5246 70 00 10
Northwest Germany VSC1 Fax: +49 5246 70 00 70
Oesternweg 12 E-mail: Reinhard.Ruehmer@kraussmaffei.com
D-33415 Verl
Germany KraussMaffei Technologies Rühmer, Reinhardt
Service Center Tel.: +49 7159 93 38 220
Süd-West-Deutschland SC2 Fax: +49 7159 93 38 249
Benzstrasse 21 E-mail: Reinhardt.Ruehmer@kraussmaffei.com
D-71272 Renningen
Germany KraussMaffei Technologies Günzel, Timo
Vertrieb und Service Center Tel.: +49 89 88 99 25 38
Süd-Ost-Deutschland VSC3 Fax: +49 89 88 99 40 98
Postfach 50 03 40 - D-80973 Munich E-mail: Timo.Guenzel@kraussmaffei.com
Krauss-Maffei-Strasse 2 - D-80997 Munich
Germany KraussMaffei Technologies Günzel, Timo
Vertrieb und Service Center Freier, Katrin
Ost-Deutschland (neue Bundesländer) VSC4 Tel.: +49 3461 25 91 940
Value Park Schkopau – Gebäude A 74 – Im Mitz II Fax: +49 3461 25 91 949
D-06258 Schkopau E-mail: Timo.Guenzel@kraussmaffei.com
Katrin.Freier@kraussmaffei.com
Argentina KHS Corpoplast Argentina S.A. Oleskow, Jorge E.
Piedras 383-5° piso, Tel.: +54 11 43 43 03 68
RA 1070 Buenos Aires, Argentina Fax: +54 11 43 43 10 80
E-mail: Jorge.Oleskow@khs.com
Australia HBM Plastics & Packaging Technologies Pty LTD Brown, Gary
46/5 Inglewood Place Tel.: +61 2 88 14 31 00
Baulkham Hills Fax: +61 2 98 99 40 69
NSW 2153 E-mail: Gary@hbm.com.au
Australia
Australia HBM Plastics & Packaging Technologies Pty LTD Kelly, Geoff
Unit 15 / 15 Thackray Rd. Neale O’Loughlin (Service)
Port Melbourne Tel.: +61 3 96 46 31 53
Victoria Australia 3207 Fax: +61 3 96 46 52 86
MX_MC6_V1.9_07.09.15_ENG
E-mail: Geoff@hbm.com.au
©KM
neale@ipn.com.au
Austria KraussMaffei Austria Ges.mbH Röttger, Holger
Brunner Straße 80 Luksch, Andrea
A-1230 Vienna Tel.: +43 1 865 58 63 22
Fax: +43 1 865 58 63 77
E-mail: Holger.Roettger@kraussmaffei.com
Andrea.Luksch@kraussmaffei.com
0-36 Preface

Bahrain IPS Schaerrer, Patrick
Dubai Airport Free Zone Tel.: +971 4 29 96 662
Office # 2W203 Fax: +971 4 29 96 322
P.O. Box 54337 E-mail: patrick.schaerrer@ips.dubai.com
Dubai, UAE
Belgium KraussMaffei Kunststofftechnik (Benelux) Van Schendel, Veronique
Minervum 7408 Van Der Schueren, Johan
NL- 4817 ZG Breda Verveer, Mark
Tel.: +31 76 57 22 522
+32 54 32 23 26
Fax: +31 76 58 75 686
+32 54 32 69 23
E-mail: Veronique.vanSchendel@kraussmaffei.com
Johan.vanderschueren@kraussmaffei.com
Mark.Verveer@kraussmaffei.com
Bolivia KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
CO - Bogota, Colombia Fax: +57 1 42 76 228
E-mail: Carlos.Cadavid@kraussmaffei.com
Brazil KraussMaffei Group do Brasil Jell, Klaus
Rua Adib Auada, 290 - Jd. Lambreta Schmatz, Oskar
06710-700 Cotia - SP Tel.: +55 11 46 12 91 71
Brazil Fax: +55 11 46 12 83 66
E-mail: Klaus.Jell@kraussmaffei.com.br
Bulgaria Plastics Bavaria Bulgaria Ltd. Hristozov, Ivan
Drava Str., nr. 3, office 1 Tel.: +359 32 96 93 96
4003 Plovdiv, Bulgaria Fax: +359 32 96 93 95
E-mail: info@plastics-bavaria.bg
Czech Kubousek s.r.o. Kubousek, Ivan
Republic Lidická 1937 Tel.: +420 38 61 02 110
CS - 37007 Ceské Budéjovice Fax: +420 38 63 51 819
Czech Republic E-mail: km@kubousek.cz
Chile Convermaq Asesorias y Representaciones E.I.R.L. Vergara, Aldo
General San Martin # 6000 Tel.: + 56 2 27 33 59 17
Oficina 203-Colina, Santiago de Chile, Fax: + 56 2 27 33 59 19
Chile E-mail: avergara@convermaq.cl
MX_MC6_V1.9_07.09.15_ENG
China Shanghai KraussMaffei Machinery Co. Ltd. Müller, Michael

©KM
(Shanghai) Building 7, No.1000, Jin Hai Road Tel.: + 86 21 50 50 96 10

Pudong New District Fax: + 86 21 50 31 50 51
201206, P.R. China E-mail: Michael.Mueller@kraussmaffei.com
Colombia KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
E-mail: Carlos.Cadavid@kraussmaffei.com
Preface 0-37

Costa Rica KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
CO - Bogota, Fax: +57 1 42 76 228
Colombia E-mail: Carlos.Cadavid@kraussmaffei.com
Croatia KMS, d.o.o. Jelenc, Matija
Poslovna cona A 25 Tel.: +386 4 25 16 150
SL – 4208 Sencur Fax: +386 4 25 16 155
E-mail: Kms@siol.net
Denmark SAXE Hansen Kristiansen, Thomas H.
Walgerholm 17 Tel.: +45 4497 70 22
DK-3500 Vaerlose Fax: +45 4497 50 55
E-mail: thk@saxe-group.com
Ecuador KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
CO - Bogota, Fax: +57 1 42 76 228
Colombia E-mail: Carlos.Cadavid@kraussmaffei.com
Egypt The Consulting Group Rhacotis Badawi, Sherif
8 Abul Maali Street - Apt. 24 Tel.: +20 2 34 60 887
ET Agouza - Cairo, Fax: +20 2 34 44 175
Egypt E-mail: sbadawi@rhacotis.com
Estonia OÜ Rolands Moisejs Vinogradov, Rivo
Peterburi tee 46 Tel.: +372 6 13 98 60
EE-11415 Tallinn Fax: +372 6 13 98 61
E-mail: rivo@rm.ee
Finland Polyservice OY Rautuoja, Osmo
Kuusimäentie 15 Tel.: +358 44 54 92 465
FI-01260 Vantaa Fax: +358 9 29 46 920
E-mail: osmo.rautuoja@polyservice.fi
France KraussMaffei Group France sas Socquet, Jacques
5 Allée des Barbanniers Tel.: +33 04 74 77 44 44
F-92632 Gennevilliers Cédex Fax: +33 04 74 73 46 64
KraussMaffei Group France sas E-mail: jacques.socquet@netstal-france.com
Netstal info@krauss-maffei.fr
65 Rue Castellion
F-01100 Oyonnax
Greece and Rigas Engineering A.E.T.E. Marinis, Panayiotis
MX_MC6_V1.9_07.09.15_ENG
Cyprus 5, Pireos str., P.O.B. 4178 Tel.: +30 210 48 54 000

©KM
GR-183 46 Moschato Fax: +30 210 48 54 199

Greece E-mail: Panayiotis.marinis@rigas-engineering.gr
Hungary KraussMaffei Austria Ges.mbH Röttger, Holger
Brunner Straße 80 Luksch, Andrea
A-1230 Vienna Tel.: +43 1 865 58 63 22
Fax: +43 1 865 58 63 77
E-mail: Holger.Roettger@kraussmaffei.com
Andrea.Luksch@kraussmaffei.com
0-38 Preface

India KraussMaffei Technologies India Pvt. Ltd. Nevatia, S.O.
Office No. 1, First Floor Tel.: +91 20 414 046 00
North Court, Opp. Joggers Park Fax: +91 20 414 046 99
Kalyani Nagar, Pune 411 006 E-mail: Sunil.Nevatia@kraussmaffei.com
India
Israel Prometheus Potashnik LTD. Potashnik, Shlomo
57/B Harimon Street Tel.: +972 9 74 66 686
60917 HARUTZIM Fax: +972 3 54 22 515
ISRAEL E-mail: prometheus@barak.net.il
Italy KraussMaffei Group Italia S.r.l. Amodeo, Gabriele
Via A. Manzoni, 1 Bottelli, Andrea
I-20023 Cerro Maggiore (MI) Panfiglio, Ivan
Binaghi, Laura
Tel.: +39 02 94 96 83 71
+39 335 28 20 23 (mobile)
+39 0331 42 12 01
Fax: +39 0331 42 21 59
+39 0331 42 12 01
+39 347 00 49 345
E-mail: gabriele.amodeo@kraussmaffei.com
andrea.bottelli@netstal.it
ivan.panfiglio@kraussmaffei.com
aura.binaghi@kraussmaffei.com
Japan KraussMaffei Japan Corporation Kanoh, Noriyuki
75-1, Nakata, Ogi, Kota-cho Tel.: +81 (0) 564 56 12 41
Nukata-gun Fax: +81 (0) 564 56 12 46
Aichi 444-0115 Japan E-mail: Noriyuki.kanoh@kraussmaffei.com
Korea KraussMaffei Korea Ltd. Don-Geun Kim
#601 Hanlim Human Tower, Tel.: +82 31 42 97 911
1-40 Geumjung-dong, Gunpo-City +82 1064 25 59 08 (mobile)
Kyunggi-Do Korea (435-050) Fax: +82 31 42 97 915
E-mail: Dg.kim@kraussmaffei.com
Kuwait IPS Schaerrer, Patrick
Office # 2W203 Fax: +971 4 29 96 322
MX_MC6_V1.9_07.09.15_ENG
Dubai, UAE
©KM
Latvia/ Rolands Moisejs Moisejs, Rolands

Lithuania Cierkurkalna 1, linija 40 Tel.: +371 67 50 16 16
1026 Riga Fax: +371 67 54 13 70
Latvija E-mail: rolands@rolandsmoisejs.lv
Luxem- KraussMaffei Kunststofftechnik (Benelux) Verveer, Mark
bourg Minervum 7408 Tel.: +31 76 57 22 522
NL- 4817 ZG Breda Fax: +31 76 58 75 686
E-mail: Mark.Verveer@kraussmaffei.com
Veronique.vanSchendel@kraussmaffei.com
Preface 0-39

Malaysia Plasmax Solutions Sdn Bhd O.C. Lim
No. 605, Block A4, Leisure Commerce Square Tel.: +60 3 74 91 07 78
No. 9, Jalan PJS 8/9 +60 3 74 91 07 80
46150 Petaling Jaya Fax: +60 3 78 77 19 23
Selangor, Malaysia E-mail: oc.lim@plasmax.com.my
Morocco Yomar s.a.r.l. Younes Lahlou
Allée Sidi Bernoussi Mekki Ziadi
35-36-37 Lotissement Banam La Gracieuse Tel.: +212 22 66 50 32
20600 Casablanca Fax: +212 22 66 50 35
Maroc E-mail: lahlou@yomar.ma
m.ziadi@fgpartners.net
Mexico KraussMaffei de México, S. de R.L. de C.V. Menconi, Ana Claudia
Pirineos 515, interior 13 Tel.: +52 44 23 09 56 00
Col. Parque Santiago, Querétaro Fax: +52 44 23 09 56 00
CP 76115 E-mail: Ana.Menconi@kraussmaffei.com
Mexico
Netherlands KraussMaffei Kunststofftechnik (Benelux) Verveer, Mark
Minervum 7408 Tel.: +31 76 57 22 522
NL- 4817 ZG Breda Fax: +31 76 58 75 686
E-mail: Mark.Verveer@kraussmaffei.com
Veronique.vanSchendel@kraussmaffei.com
New HBM LTD Brown, Gary
Zealand 4 Cavendish Drive, Manukau City Tel.: +64 9 57 95 376
P.O.Box 9270, Newmarket, Fax: +64 9 52 51 099
NZ - Auckland E-mail: gary@hbm.co.au
Norway ATM Brovig AS Rolf Kjonnerud
Syretarnet 45 Hartz, Svein
N-3048 Drammen Tel.: +47 950 77 600
Fax: +47 32 89 63 63
E-mail: rolf@atmbrovig.no
svein@atmbrovig.no
Oman IPS Schaerrer, Patrick
Office # 2W203 Fax: +971 4 29 96 322
Dubai, UAE
MX_MC6_V1.9_07.09.15_ENG
Pakistan ARN Enterprises Naeem, Azad Raza

©KM
F-7, Al Hafeez View Tel.: +92 42 35 77 49 01

67-D-1 Sir Syed Road Fax: +92 42 35 77 49 03
Liberty Commercial Zone, Gulberg-III E-mail: asad@arn-enterprises.com
Lahore, Pakistan
Panama KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
E-mail: Carlos.Cadavid@krausMaffei.com
0-40 Preface

Peru KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
Philippines KraussMaffei (Thailand) Co., Ltd. Prawit, Y.
9th Floor, Na-Nakorn Bldg. Tel.: +66 2 57 61 482
99/349 Chaengwattana road Fax: +66 2 57 61 479
Laksi, Bangkok 10210 E-mail: prawit-y@krauss-maffei.co.th
Thailand
Poland Dopak Sp. z o.o. Steiner, Ulla
ul. Sokalska 2 Tel.: +48 71 35 84 000
PL – 54-614 Wroclaw Fax: +48 71 35 84 010
E-mail: Steiner@dopak.pl
dopak@dopak.pl
Portugal FOLHADELA REBELO, LDA. Folhadela
Tv. da Areosa, 107 Tel.: +351 22 61 51 880
P – 4475–678 MAIA Fax: +351 22 61 51 889
E-mail: Folhadelarebelo@Folhadelarebelo.com
Qatar IPS Schaerrer, Patrick
Office # 2W203 Fax: +971 4 29 96 322
P.O. Box 54337 E-mail: patrick.schaerrer@ips.dubai.co
Dubai, UAE
Romania Plastics Bavaria SRL Mares, Radu
str. Iancu Jianu 26 Tel.: +40 268 41 25 59
RO-500.178 Brasov Fax: +40 268 42 52 45
E-mail: office@plastics-bavaria.ro
Russia Berstorff KraussMaffei Savranchuk, Alla
OOO BKM Tel.: +7 495 97 01 730
ul. Krasnoproletarskaja 30, Bldg. 1, 3rd floor Fax: +7 495 97 01 731
217473 Moscow E-mail: savranchuka@berstorff.ru
Saudi IPS Schaerrer, Patrick
Arabia Dubai Airport Free Zone Tel.: +971 4 29 96 662
Office # 2W203 Fax: +971 4 29 96 322
Dubai, UAE
MX_MC6_V1.9_07.09.15_ENG
Serbia- Nenel Group d.o.o. Kozoderovic, Ivan

©KM
Montenegro Radovana Grkovica 16 Tel.: +381 32 72 20 70

32300 G. Milanovac Fax: +381 32 72 20 71
Serbia E-mail: info@nenelgroup.com
Singapore KraussMaffei (Thailand) Co., Ltd. Prawit Y.
Thailand
Preface 0-41

Slovenia KMS, d.o.o. Jelenc, Matija
Poslovna cona A 25 Tel.: +386 4 25 16 150
SL – 4208 Sencur Fax: +386 4 /25 16 155
E-mail: kms@siol.net
South Africa Plastic & Chemical Trading Cockram, Roger
P.O. Box 92223 Tel.: +27 11 48 33 015
23 Orange Road, Orchands Fax: +27 11 72 83 419
ZA - Norwood 2117, Rep. of South Africa E-mail: rogerc@plastrading.com
sales@plastrading.com
Spain Coscollola Comercial S.L. Ricardo Coscollola
c/Motores, 160 Tel.: +349 3 22 32 599
E-08038 Barcelona Fax: +349 3 22 33 801
E-mail: rc@coscollola.com
Sweden Saxe Nordic Plast AB Nielsen, Ulrik G.
Friedhemsvägen 25C Herentz, Edelgard
S-552 03-Jonköping Tel.: +46 3634 18 30
Fax: +46 3634 18 39
E-mail: ugn@saxe-group.com
Switzerland KraussMaffei (Schweiz) AG Schleiss, Bruno
Grundstr. 3 Bucher, Sandra
CH-6343 Rotkreuz Tel.: +41 41 79 97 180
Fax: +41 41 79 97 181
E-mail: bruno.schleiss@kraussmaffei.com
sandra.bucher@kraussmaffei.com
Syria Namaco International Maatouk, Nabil
Dalaty Bldg. Kallas, Mazen
Ghazwet Bader St 1 Tel.: +963 11 37 49 80 90
Al Muhajerren Fax: +963 11 37 35 72
Damascus - Syria E-mail: maatoukn@namaco-me.com
namaco@mail.sy
kallasm@namaco-me.com
Taiwan KEMA International Machinery Limited Tsai, Emma
Room 2305A, 23 Floor, World Wide House Tel.: +886 4 23 10 95 08
19 Des Voeux Road Central Fax: +886 4 23 10 86 95
Central, Hongkong E-mail: emma.tsai@kema.tw
Thailand KraussMaffei (Thailand) Co., Ltd. Prawit Y.
MX_MC6_V1.9_07.09.15_ENG

©KM

Thailand
0-42 Preface

Turkey TEPRO Makine ve Otomasyon Dogan, Semih
Sistemleri Ticaret Ltd. Sti. Saygin, Cem
Mimar Sinan Mh. Bosna Cd. Tel.: +90 212 27 01 320
Colpan Sk. No:2 +90 212 27 01 323
34782 Cekmeköy +90 212 27 03 463
Istanbul, Turkey +90 212 27 02 264
Fax: +90 212 27 08 995
E-mail: semih.dogan@tepro.com.tr
cem.saygin@tepro.com.tr
Ukraine Vladimir Grigorievich Kulik Kulik, Vladimir G.
Repina Str. 18/52 Tel.: +380 67 29 01 060
21032 Vinnica Fax: +380 432 26 94 08
Ukraine E-mail: immservice@voliacable.com
immservice@yandex.ru
United Arab IPS Schaerrer, Patrick
Emirates Dubai Airport Free Zone Tel.: +971 4 29 96 662
Office # 2W203 Fax: +971 4 29 96 322
Dubai, UAE
United KraussMaffei (U.K.) Ltd. Bate, Mike
Kingdom Europa Boulevard Tel.: +44 1925 64 41 00
Gemini Business Park Fax: +44 1925 23 42 84
GB - Warrington E-mail: Mike.Bate@ kraussmaffei.co.uk
WA5 5TR
USA KraussMaffei Corporation Paul Caprio
7095 Industrial Road Tel.: +1 859 28 30 200
Florence, KY 41042 Fax: +1 859 28 30 290
USA +1 859 28 39 631
E-mail: Paul.Caprio@kraussmaffei.com
Venezuela KraussMaffei Andina Cadavid, Carlos
Cra 68D # 25B - 86. Of. 626 Tel.: +57 1 42 76 227
Vietnam KraussMaffei (Thailand) Co., Ltd. Prawit Y.
MX_MC6_V1.9_07.09.15_ENG

©KM
Thailand
Preface 0-43
0.11 Index of abbreviations
Abbreviations Meaning
2K machine 2-component machine (= machine with at least two injection units)
ABS Acrylonitrile butadiene styrene
AEE ActiveSphere Executive Environment
AF Automatic feed unit
b/w black/white
BDE Production Data Acquisition
BMC Bulk Mold Compound
CA Cellulose acetate
CA Charge amplifier
CAB Cellulose acetate butyrate
CIMI Common Injection Molding Interface
CLG Cooling unit with external heat-balancing unit of type "Chiller"
Cm/Cmk Machine capability index
CP Cellulose propionate
Cp/Cpk Process capability index
Dec. Decrement (=reduce in steps)
DIN German Institute for Standardization
EC European Community
EEC European Economic Community
EMC Electromagnetic compatibility
EN European standard
Ext. External
FA mode Fully automatic mode
FCS Flux Control Systems
FP Fixed mold platen
FTP File Transfer Protocol
H Heating
HBG Temperature control with external heat-balancing unit of type "Mold Temperature Controller"
HDPE High density polythene
HSVN Hydraulic Needle Shut-Off
HSVS Hydraulic Sliding Shut-Off
HTV High Temperature Vulcanization
IMM Injection molding machine
Inc. Increment (= increase in steps)
MX_MC6_V1.9_07.09.15_ENG
Inj. unit Injection unit

©KM
IPC Industrial Personal Computer

ISO International Organization for Standardization
K Cooling
LH fuse Low voltage, high-breaking-capacity fuse
LSR Liquid Silicone Rubber
M mode Manual mode
MLD Mold
MP Movable mold platen
MSL Mean Sea Level
0-44 Preface
NBR Nitrile Butadiene Rubber
No. Number
OD Duty cycle
OEG Upper intervention limit
Ophc Operating hours counter
ORS Operator rearside
OS Operator side
OSG Upper specification limit
PA Polyamide
Par. Parameters
PBTP Polybutylene terephthalate
PC Polycarbonate
PE Polythene
PID-Mode Proportional Integral Differential control mode
Plast., Plastif. Plasticizing / Plasticizing unit
PMMA Polymethyl methacrylate
POM Polyoxymethylene
Pos. Position
PP Polypropylene
PPO Polyphenylene oxide
Pr. Pressure
Prog. Programmable
PS Polystyrene
PSU Polysulfone
PSVN Pneumatic Needle Shut-Off
PTFE Polytetrafluoroethylene
PU Polyurethane
PV control Pressure/speed control
PVC Polyvinylchloride
RFL Return-flow lock
RPM Reaction technology / PUR processing
S mode Setting mode
SA mode Semi-automatic mode
SAN Styrene acrylonitrile
SB (=PS) Polystyrene
SP Injection unit, injector
MX_MC6_V1.9_07.09.15_ENG
SPI Society of the Plastic Industry

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Std.dev. Standard deviation

SVN Needle shut-off nozzle
SVO Open nozzle
SVS Sliding shut-off nozzle
Sync. Synchronization
TCP Transmission Control Protocol
Temp. Temperature
Tol. Tolerance
UEG Lower intervention limit
Preface 0-45
USB Universal Serial Bus
USG Lower specification limit
VARAN Versatile Automation Random Access Network
(= wired data network technology for local data networks)
VDE Association for Electrical, Electronic & Information Technologies
ZE Auxiliary device
MX_MC6_V1.9_07.09.15_ENG
©KM
0-46 Preface
1 Safety
This chapter provides basic instructions
• regarding the safety of the machine,
• regarding necessary measures and symbols,
• on the duties of the user and operating staff,
• regarding liability matters.
1.1 Symbol and explanation of notes . . . . . . . . . . . . . . 48
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . 53
1.3 Intervention or access points . . . . . . . . . . . . . . . . . 71
1.4 Safety at the machine . . . . . . . . . . . . . . . . . . . . . . . . 72
1.5 Inspection of safety devices . . . . . . . . . . . . . . . . . . 92
1.6 Pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . 104
1.7 Hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Safety test/safety instruction . . . . . . . . . . . . . . . . . . 107

MX_MC6_V1.9_07.09.15_ENG
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Safety 1-47
1.1 Symbol and explanation of notes
1.1.1 General symbols
w
d
D
Hazard
This symbol indicates a direct threat to the life and health of persons.
Failure to observe these instructions will result in severe harmful effects,
including fatal injury.
w
D
Warning!
This symbol indicates a possible threatening hazard for the life and health of
persons.
If these instructions are ignored, the consequence may be serious damage to
health and possibly even fatal injury.
D
w
Caution
This symbol indicates a possible hazardous situation.
Failure to observe these obstructions may result in injuries or cause material
damage.
W
Important
This symbol provides important instructions regarding proper use of the
machine.
Failure to observe these instructions may result in faults of the machine or
problems in the surrounding area.
I
Note
This is the symbol accompanying tips on use of the machine and other
particularly useful information.
MX_MC6_V1.9_07.09.15_ENG
This information makes it possible to make best use of all of the machine
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functions.
a
B
Observe the operating manual
All persons assigned to working on the machine must have read and
understood the operating instructions before performing the work.
1-48 Safety
i
t
Environmental note
This symbol refers to disposal in an environmentally compatible way of
environmentally harmful operating and cleaning substances.
1.1.2 Instructions regarding specific hazards
e
d
D
Risk from electrical system
This symbol indicates a direct threatening hazard for the life and health of
persons as a result of the effects of electrical energy.
l
d
D
Hazard from falling loads
This symbol indicates a direct threat to the life and health of persons as a result
of suspended loads during transport.
Use only lifting equipment which corresponds to safety requirements.
H
d
D
Risk from hot surfaces
persons as a result of hot surfaces at the machine.
f
d
D
Fire hazard
This symbol indicates a direct threat to the life and health of persons and for
damage to the machine as a result of flammable material.
MX_MC6_V1.9_07.09.15_ENG
through to fatal injuries and leads to damage to property.

©KM
h
d
D
Risk from hydraulic or pneumatic systems
This symbol indicates a direct threat to the life and health of persons resulting
from components or operating materials of hydraulic or pneumatic systems.
Safety 1-49
r
d
D
Risk of slipping
persons as a result of the risk of slipping in the area of the machine.
s
d
D
Risk from harmful dusts or vapours
persons resulting from harmful dusts or vapours from the machine.
S
d
D
Risk of spraying
This symbol indicates a direct threat to the life and health of persons from
pressurized fluid material, which may be very hot or very cold.
q
d
D
Danger of crushing
persons as a result of the risk of crushing injury at machine components.
L
1
R
Entry prohibited
This symbol indicates a direct threat to the life and health of persons who wish
to gain access to areas of the machine.
It is prohibited to access the appropriately marked work area.
MX_MC6_V1.9_07.09.15_ENG

©KM
B
m
Load attachment points
The attachment points for lifting the machine are identified on all machines with
the symbol illustrated.
The machine must only be suspended at these points for transport.
1-50 Safety
L
p
R
Prohibition of people wearing pacemakers
persons fitted with heart pacemakers. Such persons must not enter the work
area.
including life-threatening situations.
1.1.3 Protective clothing

The following symbols are given in the operating instructions at points where the
operating personnel is obliged to wear protective clothing.
Wear close-fitting clothing in order to avoid accidents.
In particular, ties, scarves, rings or chains must not be worn because they can get
caught on moving parts of the machine.
If you have long hair, please wear suitable head covering.
The operating personnel is obliged to wear the following protective clothing:
y
B
Protective gloves
The injection molding process produces workpieces with high temperatures
and which may also have sharp edges.
Workpieces, molds or residual material must, therefore, never be touched with
the bare hand.
You must not wear safety gloves if there is a risk of the gloves being caught,
e.g. by rotating parts of electric drills.
b
B
Safety shoes
To prevent feet being crushed, safety shoes with a steel toe-cap must be worn.
G
B
Eye protectors
When working with hydraulic oil, safety goggles must be worn.
MX_MC6_V1.9_07.09.15_ENG
Hydraulic oil which splashes out can result in severe eye injury or even in the
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loss of eyesight.
k
B
Protective helmet with face mask
Always wear a protective helmet with facial protection when conducting set-up
work with the safety gate open and work in the nozzle area.
Material which splashes out can result in severe eye injuries or even in the loss
of eyesight.
Safety 1-51
E
B
Hearing protection
A constantly high noise level results in damage to your hearing.
For this reason, wear ear protection when in the area of the operating
machine.
Noise protection devices must not be removed.
N
B
Protective helmet
A protective helmet must always be worn:
• when there is a risk of head injuries, particularly from molds or workpieces
dropping off,
• when performing installation and disassembly work overhead,
• and with cranes,
Z
B
Protective clothing
If the safety gate is open, it is still possible for hot, plasticized melt to flow out
of the nozzle under pressure.
Always wear protective clothing and take appropriate safety precautions
according to the accident prevention regulations when conducting set-up work
with the safety gate open or work in the nozzle area.
MX_MC6_V1.9_07.09.15_ENG
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1-52 Safety
1.2 General safety instructions
1.2.1 Instructions contained in the operating manual

A basic requirement for safe use and trouble-free operation of this machine is
proper knowledge of the fundamental safety instructions and of the safety
precautions.
This operating manual contains the most important instructions to enable the
machine to be operated in a safe manner.
The contents of this Operating Manual, in particular the safety instructions, must
be strictly observed by all personnel working on the machine.
The operating company and operating personnel must also observe the rules and
regulations for accident prevention and for environmental protection valid at the
point of installation.
1.2.2 Obligation on the part of the owner/operator
W
Important
The operating company must ensure that the complete printed operating
instructions are available at all times to operating personnel.
The operating company undertakes to allow only qualified and instructed

personnel to work on the machine:
• Personnel must be familiar with the fundamental regulations regarding safety
at work and accident prevention and have been instructed in the use of the
machine,
• Personnel must have read the "Safety" chapter and the warning instructions
in this operating manual and confirmed by their signature that they have
understood them.
Obligation to co-operate of the operating company

The operating company undertakes to co-operate in the discovery of possible
safety risks to personnel and machinery that are still unknown. In particular, the
operating company must carry out the following:
• A risk assessment based on the labour protection laws, ordinance on
MX_MC6_V1.9_07.09.15_ENG
industrial safety and health or other national specifications.

• Notify KraussMaffei of undetected dangers that have not yet been mentioned
©KM
in these operation instructions.

• Report accidents and near accidents to KraussMaffei.
Safety data sheets

The owner/operator ensures that the safety data sheets (in accordance with
91⁄155⁄EEC) and regulations issued by the raw material manufacturer will be read
carefully and observed. It must also be ensured that no new hazards are
presented by compounds or mixtures of raw materials.
Safety 1-53
The safety data sheets must be passed on to all persons who come into contact
with the raw materials.
1.2.3 Obligation on the part of the personnel

All persons who are assigned the task of working on the machine, have the
obligation, before commencing work:
• to read through the operating manual in full,
• to read carefully the safety data sheets (in accordance with 91⁄155⁄EEC) and
regulations and to observe them,
• to follow basic regulations on health, safety and the prevention of accidents,
• to read the "Safety" chapter and the warning instructions in this operating
manual and to confirm by their signature that they have understood them.
1.2.4 Training personnel

• Only trained and instructed personnel may work on the machine.
• The legal minimum age for the operating personnel absolutely must be
observed.
• Clearly define the responsibilities of the personnel in respect of operation,
setting-up and maintenance.
• Trainee personnel must operate the machine only under the supervision of an
experienced person.
Persons Instructed Persons with Persons with Superior with

persons technical electrotechnical appropriate
Activity training training expertise
Packaging, transport X X -- X
Commissioning -- X X X
Operation X X X X
Fault finding -- X X X
Rectifying Faults -- X -- X
Mechanical, pneumatic, hydraulic
Rectifying Faults -- -- X X
Electrical
Setting, setting-up -- X X X
Maintenance X X X X
Upkeep -- X X X
MX_MC6_V1.9_07.09.15_ENG
Taking machine out of service, placing -- X X X

into storage
©KM
1-54 Safety
1.2.4.1 Requirements in respect of the operating and maintenance personnel

• Each person involved with the erection, installation, commissioning, operation
and maintenance of the machine must - before taking any action at all - have
read and understood the technical documentation and, in particular, the
"Safety" chapter.
• Operation and repair of the machine must only be carried out by persons who
have received professional training appropriate to the nature of the activity.
This applies, in particular, to work on the electrical, pneumatic, hydraulic or
nitrogen equipment of the machine.
• After completion of the installation work by qualified employees of
KraussMaffei or by their authorized representatives, the operating and
maintenance personnel of the owner/operator shall receive instruction in the
use of the machine.
• The owner/operator has an obligation to teach any operators and
maintenance staff who join later how to operate and maintain the machine;
this instruction must be as full and as careful as the original instruction and
must take account of all safety regulations.
• Persons receiving training, trainee personnel, persons receiving instructions
or undergoing general training, must only be allowed to work at the machine
under the constant supervision of an experienced person.
• If several persons are working on the machine, the responsibilities for the
individual tasks must be clearly defined by the owner/operator and they must
be maintained. For reasons of safety, there must be no uncertainty with regard
to areas of responsibility.
MX_MC6_V1.9_07.09.15_ENG
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Safety 1-55
1.2.4.2 Safety instructions for the operating and maintenance personnel
w
d
D
Hazard
Before stepping onto the machine, secure any movable separating safety
devices or gates to prevent them closing.
It is important to ensure that any movable separating safety device is closed
from the outside during the time a person is present in the work area.
Before restarting the machine, always ensure that there is no person present
in the hazardous area of the machine.
• Each person involved with the erection, installation, commissioning, operation

and maintenance of the machine must - before taking any action at all - have
read and understood the technical documentation and, in particular, the
"Safety" chapter.
• If any modifications are made to the machine which affect safety aspects or if
any operational problems occur, the machine must be switched off
immediately and safeguarded. Immediately report the fault to the
position⁄person responsible and arrange to have it rectified.
• Avoid any method of operation which is not in conformity with safety
instructions.
• Before switching on or starting the machine, ensure that no person is at risk
from the machine starting up.
• When the machine is running, do not switch off or remove any extraction and
ventilation devices.
• On programmable control systems, it is prohibited to make any program
changes (software) that impair the safety of the machine.
• Keep the workplace and access points free of tools, appliances and other
objects.
• Keep the place of work and the area around the machine clean and tidy at all
times.
• Safety keys must be kept only by persons who have received proper training
and are authorized to work with the following devices:
– electrical control cabinets,
– terminal boxes,
– adjustable equipment (hydraulics, pneumatics),
MX_MC6_V1.9_07.09.15_ENG
– equipment which is installed for safety purposes.

• Neither limit switches, safety valves nor any other monitoring or control
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elements involved in the process, may be operated in a wilful or thoughtless

manner. This may result in injury to persons or damage to the machine.
1-56 Safety
1.2.5 Hazards in use of machine

The machine has been built in accordance with the latest state of the art and the
recognized rules of technical safety. Nevertheless, when using the machine,
hazards may exist for life and limb of the user or third parties or the risk of damage
to the machine or other material property.
Only operate the machine when the following prerequisites have been met:
• The area of application corresponds to the intended use (see section 0.1,
page 0-26).
• The safe technical condition has been checked and is in correct working
order.
Eliminate all faults immediately.
1.2.6 Hazards resulting from electrical energy

• The electrical connection of the machine to the power supply network and
also work on the electrical equipment and in the control cabinet must only be
carried out by qualified professional persons in conformity with the
appropriate regulations and provisions applicable to the point of installation.
• Inspect the electrical equipment of the machine at regular intervals.
• Eliminate immediately any loose connections and damaged cables.
• Always keep the control cabinet closed. Access is permitted only for
authorized persons with a key or tool.
1.2.7 Hazards resulting from hydraulic system

• As a result of the media which are expelled at high pressure, there is a risk of
injuries, explosion and fire.
• Avoid naked flames and objects with hot surfaces when carrying out work on
the hydraulic system.
• If damage such as chafing points or leaks can be seen on pressure hoses,
pressure lines and screw connections, switch the machine off immediately,
even if the deficiencies are only slight. Restarting the machine is not permitted
until the deficiencies have been rectified.
• Incorrectly set operating pressures are a source of hazards. For this reason,
comply with the operating pressures which are stated in the specifications.
• Inspect the hydraulic operating pressure by regularly checking the pressure
indicators.
MX_MC6_V1.9_07.09.15_ENG
• You must not work on the corresponding hydraulic equipment until you have
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checked the Minimess connections to ensure that the corresponding subarea

of the hydraulic system is depressurized.
Safety 1-57
1.2.8 Hazards resulting from pneumatic system

• As a result of the media which are expelled at high pressure, there is a risk of
injuries, explosion and fire.
• If damage such as chafing points or leaks can be seen on pressure hoses,
pressure lines and screw connections, switch the machine off immediately,
even if the deficiencies are only slight. Restarting the machine is not permitted
until the deficiencies have been rectified.
• Exceeding the operating pressure stated in the specifications jeopardizes the
safety of the operating personnel and of persons who are within the
surrounding area of the machine.
• Whenever you access the pneumatic system, shut off the main line
beforehand. Ensure that the cylinders have been completely emptied of
pressure.
• You must not work on the corresponding pneumatic equipment until you have
checked the Minimess connections to ensure that the corresponding subarea
of the pneumatic system is depressurized.
1.2.9 Emission of harmful dusts and vapours

Various plastics which are processed on injection molding machine, may emit
gases, vapours or dusts which are harmful to health; this necessitates the use of
a suitable extraction system.
The owner/operator must, therefore, provide sufficient ventilation or extraction. If
you have any questions, do not hesitate to contact KraussMaffei Service.
1.2.10 Hazards resulting from harmful fluids

Lubricating oils, hydraulic oils, cooling oils and emulsions are harmful to the
environment. It is essential to observe national regulations.
Only tried and tested, branded, cooling lubricants may be used. Lubricants and
cooling lubricants are essential for the sliding properties and guide tracks.
The following sealing materials and scrapers common in mechanical engineering
must be safe from corrosive attack
• Nitrile rubber (NBR)
• Polyurethane (PUR)
• Viton
• Two-component paints (DD paints)
MX_MC6_V1.9_07.09.15_ENG
©KM
It is essential to prevent the following:

• the limits for harmful or environmentally-polluting elements being exceeded,
• the formation of flammable mixtures,
• machine elements (in particular cables, connectors, seals) sustaining
damage.
This applies, in particular, if any change is made to the product originally used.
1-58 Safety
The substances may

• be easily flammable,
• form harmful vapours,
• result in irritations to the skin and allergies.
There is a risk of slipping if there is an uncontrolled leakage of such substances.
Collect the fluids in troughs according to the current local regulations and dispose
of them appropriately.
1.2.11 Hazards during injection molding
y
B
Protective gloves
Ensure necessary protection by wearing safety gloves or using other suitable
aids (supports, bases, etc.).
k
B
work with the safety gate open and work in the nozzle area and fill opening.
of eyesight.
Z
B
Protective clothing
of the nozzle under pressure.
There is a major risk of injury and the possibility of damage to equipment when
working with plasticized injection melt, injection molding parts and all heated
components of the injection molding machine.
As a consequence of insufficient drying or of build-down in certain plastics,
MX_MC6_V1.9_07.09.15_ENG
material may spray unintentionally out of the nozzle or there may be a reduction
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in pressure on the mold mass in the mold.

Plasticized injection melt may emerge in the mold area
• during operation with hotrunner molds with contacting nozzle and opened
nozzle shut-off (or without nozzle shut-off),
• with opened shut-off nozzle in mold.
Due to residual moisture, thermal decomposition, propellants or slug formation,

hot melt can be ejected at high speeds from the nozzle or fill opening.
Safety 1-59
When working on heated screw barrels (e.g. cleaning, centring the nozzle,
changing nozzles, removing the hopper block), suitable personal protective
equipment must be worn:
• Protective helmet with face mask
• Heat-protection gloves
• Long-sleeved work clothes
For adjustment work when the system is heated up, the material in the barrel must
be known. Observe the instructions included in the safety data sheet for the
plastic.
Special caution is required for plastics that decompose under excessively high
temperatures or excessively long dwell times and can build up high pressure (e.g.
POM, PA GF, PVC, flameproof materials).
MX_MC6_V1.9_07.09.15_ENG
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1-60 Safety
1.2.12 Hazards during foaming
y
B
Protective gloves
Ensure necessary protection by wearing safety gloves or using other suitable
aids (supports, bases, etc.).
k
B
work with the safety gate open and all work in the nozzle and clamping area.
of eyesight.
Z
B
Protective clothing
of the nozzle or hotrunner under pressure.
W
Important
• The operating company is responsible for the operational reliability of the
mold shut-off nozzles.
• Hotrunner molds without a mold needle shut-off are not suitable for foaming
work.
During foaming, the gas-laden melt represents an additional risk of injury and the
possibility of damage.
For process-related reasons, open hotrunner molds should not be used.
As a result of the gas nucleation, accidental ejection from the hotrunner is
MX_MC6_V1.9_07.09.15_ENG
possible in this case, or with opened shut-off nozzles in the mold, or a load relief
of the mold melt in the hotrunner can result, which can lead to the discharge of
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plasticized, gas-laden injection melt in the mold area.
Safety 1-61
1.2.13 Dangers in mold area
D
r
d
Risk of slipping
Ensure the area on which you step is clean and dry when entering the work
area.
H
d
D
Risk of burns on heated mold components.
Take suitable protective measures in accordance with accident prevention
regulations.
1.2.13.1 Hazards when changing the mold
q
d
D
Crushing hazard
• The dimensions of the protective panelling of the mold area and of the
ejector chute are designed in such a way as to comply with the safety
clearances contained in the requirements of the safety regulations and
DIN EN 201, provided that the dimensions of the mold are less than or
equal to the dimensions of the mold clamping platen.
• If larger molds are used, it is necessary to provide for additional safety
measures to prevent any person reaching over or under the mold area.
• The safe distances as per DIN EN ISO 13857, table 1, must be maintained.
w
D
Caution
• KraussMaffei can only guarantee machine safety if the mold dimensions
are not larger than the dimensions of the mold clamping platens.
• For molds with energy storage, the safety regulations of the mold
manufacturer must be observed.
• The mold must only be changed when the machine is in a suitable position.
MX_MC6_V1.9_07.09.15_ENG
• To avoid severe damage to the machine, never leave tools or other objects
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lying around in the work area.

• When changing the mold, secure the machine to prevent it restarting (if
necessary, secure movable safety gates or guards with a padlock to prevent
them closing unintentionally).
• When subsequently preheating the mold, ensure that a protective cover is
fitted to the sprue opening of the mold.
The protective cover prevents slugs from being hurled out of the sprue
opening during preheating.
1-62 Safety
1.2.14 Warranty and liability

Our "General Terms and Conditions of Sales and Delivery" are basically
applicable. These shall be provided to the owner/operator no later than at the
conclusion of the contract. Warranty and liability claims related to injury to
persons or material damage are excluded if they are attributable to one or several
of the following causes:
• Use of the machine not in conformity with the provisions and specifications.
• Unprofessional installation, commissioning, operation and maintenance of
the machine.
• Operation of the machine with faulty safety devices or with safety and guard
devices not properly attached or not operational.
• Failure to observe the instructions in the operating manual concerning
transport, storage, dismantling/installation, commissioning, operation,
maintenance or setting up of the machine.
• Any modifications to the machine carried out by the operator.
• Any changes to the machine carried out by the operator (e.g. drive ratios:
power/capacity and speed).
• Defective monitoring of machine components which are subject to normal
wear-and-tear.
• Improperly performed repairs.
• Major catastrophes resulting from the effect of foreign parts and "force
majeure".
1.2.15 Organizational measures

The owner/operator must provide the necessary personal protective equipment
for the operating, maintenance and repair personnel and ensure that this
equipment is also worn when working on the machine.
Ensure that sufficient light is available, depending on the mode of operation and
work carried out on the machine.

The machine must only be operated if all safety devices and safety-related
devices, such as separating safety devices, emergency-stop devices, noise
insulation, extraction devices, are fitted and operational.
Safety devices must never be removed, disabled or otherwise impaired in their
MX_MC6_V1.9_07.09.15_ENG
function.
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The machine must not be operated when the protective panelling of the screw
barrel is dismantled. Otherwise, there is no longer any protection against touching
the heated surfaces underneath.
When the safety mechanisms are manipulated, the owner/operator must expect
the following dangers:
• severe physical injuries,
• fatal injuries.
Safety 1-63
1.2.17 Informal safety measures

• Always keep the operating manual at the machine at all times and in an easily
legible condition.
• In addition to the operating manual, observe the generally applicable as well
as local regulations regarding accident prevention and environmental
protection.
• The owner/operator must make these regulations available to the operating
personnel.
• The owner/operator must keep all safety and hazards instructions at the
machine in a legible condition and replace instructions as necessary.
1.2.18 Safety measures during normal operation
w
d
D
Risk of injury, explosion or fire
• Foreign parts (removed gates, frozen melt, loose parts, plastic materials,
etc.) may adversely affect the safety functions or deactivate them.
• A risk of injury, explosion and fire exists from hydraulic oil flowing out at
high pressure or leaks.
• The temperature on the surface of the heating bands of the screw barrel
is significantly higher than the displayed actual temperature at the
operating/display panel. Therefore, keep the heater band surfaces free of
any objects and dirt (e.g. plastic, cloths, etc.).
w
D
Caution
Risk of injury and damage to the barrel due to excessively high temperature or
injection pressure.
Observe the values on the identification plate of the plasticizing unit!
• Inspection the machine on a daily basis, and when required, to ensure that
there are no foreign parts in it. Remove all foreign parts from the machine
immediately.
• Hydraulic oil on a hot surface presents a risk of fire. It is therefore necessary
to immediately eliminate any leakages and damage to the line system.
MX_MC6_V1.9_07.09.15_ENG
• The owner/operator shall ensure that the machine is not operated

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unintentionally or that start-up functions are carried out unintentionally.

• The machine must only be operated if all safety devices are operating
properly.
• Before switching on the machine, ensure that no person is at risk from the
machine starting up.
• Inspect the machine for any damage that is recognizable from the outside,
and for proper operation of the safety devices daily and as required.
1-64 Safety
1.2.19 Fire protection

Precautionary measures
• Adapt the fire extinguishing equipment and extinguishing operations to the
materials and products in use at the machine. Enquire at
manufacturer/supplier regarding the requirements.
• Use carbon dioxide⁄foam extinguisher.
• Do not extinguish with water.
• Mark the information relating to fire extinguishing operations clearly at the
installation point of the machine to thus assist the firefighting forces.
• The owner/operator must regularly instruct his personnel and clarify the
following:
– Where is the nearest fire extinguisher located?
– Where is the nearest fire alarm located?
– Where is the nearest telephone located?
– What is the emergency number of the fire service?
Conduct in the event of a fire

1) Raise the alarm
Provide the following information in the event of a fire:
• Where is the fire located?
• What is on fire?
• How many persons are injured?
• Who is reporting it?
When reporting a fire, wait for questions that you may be asked.
2) Switch off the machine immediately.
• To do this, press the emergency-stop button (red mushroom-shaped
button with yellow background) and
• switch off the machine at the master switch.
3) Give injured persons first aid without delay.
4) Extinguish fire that has broken out.
Measures to extinguish the fire or to prevent it spreading are only permitted if
it is possible to take them without posing a danger to life and limb.
5) Direct the fire brigade to the source of the fire as soon as they arrive.
1.2.20 Conduct in an emergency

MX_MC6_V1.9_07.09.15_ENG
Switch the machine off by operating one of the emergency-stop buttons (red
mushroom-shaped button, with yellow background).
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• Press the emergency-stop button if

– there is a risk to human life.
– there is a danger that the machine or the mold will be damaged.
• Activate the "EMERGENCY STOP" function by operating the respective
emergency-stop button.
Further action must follow the accident prevention regulations which have been
laid down.
Safety 1-65
1.2.21 Safety when carrying out maintenance, repair and fault rectification work
The owner/operator must perform the prescribed setting, maintenance and
inspection work according to the required schedule.
Before commencing any maintenance work and repair work (see section 10.5,
page 10-704) always take the following safety precautions in the order stated:
1) Switch off the machine.
2) Switch off the master switch and secure the master switch with a padlock
(see section 1.4.8, page 1-85) to prevent it being switched on again
unintentionally.
3) Also switch off any external voltage circuits present.
4) Depressurize the hydraulic and pneumatic systems.
5) Secure the repair area, to the extent necessary. Affix warning plates.
6) Ensure that the parts to be touched have cooled down to room temperature
before commencing the maintenance work.
7) Position the device in such a way that the intervention point is easily
accessible.
8) If necessary, securely support the vertical slides or similar machine parts.
Ensure that during maintenance work

• machine operations can be performed,
• no media are present which are pressurized,
• no electrical voltages exist.
1.2.21.1 Fundamental information on maintenance and repair work

• Maintenance operations must only be carried out by persons who have
received professional training appropriate to the nature of the activity.
• Inform the operating personnel before commencing any special work and
repair operations and appoint a supervisor.
• Attach major subassemblies carefully to lifting gear when replacing them.
• Workshop equipment adequate for the work to be carried out is essential
when performing any maintenance work.
• Once loose screw connections have been retightened, check that they are
firmly fitted.
• If protective panelling and safety devices have been removed in order to carry
out maintenance and repair operations, such devices must be fitted on again
immediately after completing the maintenance and repair operations, and
MX_MC6_V1.9_07.09.15_ENG
check to ensure they operate properly.

©KM
• When carrying out removal and installation work above head height, use
ladders and work platforms which comply with safety regulations. In
accordance with the prevailing accident prevention regulations, these ladders
and platforms must not be equipped with rollers.
• Do not use parts of the machine as an aid for climbing.
• When carrying out maintenance operations at high height, use fall protection
equipment.
• Keep all handles, steps, railings, landings, platforms and ladders free of dirt
and lubricants.
1-66 Safety
• Only components and corresponding securing elements from KraussMaffei -

or those specified or supplied by KraussMaffei - may be used.
This equally applies to nozzles, plasticizing⁄injection barrels and the
corresponding securing elements.
1.2.21.2 Safety when working on electrical equipment
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Hazard
Work on the electrical equipment and in the control cabinet must only be
carried out by qualified professional persons while complying with the
regulations and revisions applicable at the point of installation.
• If inspection, maintenance or repair work has to be performed on machine

and system parts - if prescribed - render them voltage-free before starting the
work.
• First check that isolated parts are voltage-free, then earth and short-circuit
them. Isolate adjacent, live parts.
• If it is necessary to carry out work on live parts:
– a second person must be made available who, in an emergency, is able
to operate the emergency-stop button or the master switch and to switch
off the voltage,
– the work area has to be blocked off with a red-and-white safety chain and
a warning sign,
– you must only use tools insulated against voltage.
• When working on high-voltage assemblies after the voltage has been
disconnected,
– connect the supply cable to earth and
– short-circuit capacitors with an earthing rod.
• Use only the original fuses approved for the prescribed amperage.
• If any faults exist at the power supply, switch the machine off immediately.
• When working with earthed tools, such as soldering irons, hand electric drills
and similar equipment, switch off the master switch of the machine and any
external voltage circuits present.
• Printed circuit boards or plug connections must only be removed and
disconnected if the machine or the relevant equipment is not energized.
MX_MC6_V1.9_07.09.15_ENG
• Cover over connectors not used with dummy caps or dummy connectors to
prevent dirt.
©KM
• Beware of stored electric charges.

• Check the parts with a measuring device to ensure that they are voltage-free.
Safety 1-67
1.2.21.3 Safety when working on hydraulic/pneumatic system
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Important
Work on the hydraulic/pneumatic systems must only be carried out by qualified
professional persons while complying with the regulations and revisions
applicable at the point of installation.
Make use of your personal protective equipment (eye protection, safety shoes,
protective clothing, etc.) when carrying out work on the hydraulic/pneumatic
system.
Before detaching a line or removing a control or drive unit:
• render the system pressureless,
• lower or secure detached loads,
• switch off pumps,
• relieve pressure accumulator.
Check at the pressure indicator whether the system is in fact depressurized, also
on machines with automatic pressure relief.
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Hazard
Hydraulic⁄pressure accumulators are equipped with safety valves (pressure
limiting valves). The safety valves have a fixed setting and are provided with
an anti-tamper seal.
The setting must not be altered and the anti-tamper seal must not be removed.
The inspection and maintenance of pressure accumulators must be carried out in

conformity with national regulations.
• Use only nitrogen for filling pressure accumulators.
• Pay attention to the prefill pressure of the nitrogen cylinders.
• Use only the specified filling and testing devices when working on pressure
accumulators.
If the cylinder pressure is higher than the maximum operating pressure of the
pressure accumulator, a tested safety valve must be connected between the two
MX_MC6_V1.9_07.09.15_ENG
components.
©KM
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Risk of injury, explosion or fire
A risk of injury, explosion and fire exists from hydraulic oil flowing out at high
pressure.
It is therefore necessary to immediately eliminate any leakages and damage
to the line system.
1-68 Safety
• Inspect pressure hoses and lines as well as screw connections at regular

intervals in accordance with current standards to ensure that they are in
proper condition and to ensure that their applicable service or storage life has
not expired, and replace components immediately even if only slight damage
is present.
• Regularly replace the pressure hoses in accordance with the prevailing
regulations and in accordance with the specifications in the "Maintenance and
Servicing" Chapter.
• Route and install hydraulic lines and compressed air lines in a professional
manner and in accordance with valid standards and regulations.
Line fittings, as well as the length and quality of the hose lines must also comply
with requirements.
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Important
The connections must not be changed.
Damage to pipes, hoses and machine parts may occur if the hydraulic system is
not bled when the machine is restarted after the completion of repairs or work on
the system.
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Environmental note
Prevent oil leaking into the ground under all circumstances.
1.2.22 Constructional modifications to the machine

• Do not carry out any modifications, attachments or conversions to the
machine without the approval of KraussMaffei. This also applies to welding at
load-bearing parts.
• Any conversion measures require the written approval of KraussMaffei
company. If you nevertheless carry out modifications or conversions to the
machine without the written approval of KraussMaffei, this will result in any
MX_MC6_V1.9_07.09.15_ENG
warranty claim being void.

©KM
• Always replace all machine parts immediately which are not in proper
condition.
• Use only original replacement and wear parts. If parts from other sources are
used, there is no assurance that these parts are designed and manufactured
in conformity with the safety requirements and to withstand the stresses which
occur.
Safety 1-69
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Warning!
If auxiliary devices fitted to the injection molding machine are removed, the
original safety devices must be refitted and the control-related safe status must
be restored.
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Important
The machine manufacturer is only responsible for the interaction of the
machine with the auxiliary devices if the interface was connected by the
machine manufacturer himself.
If the owner/operator of the machine also performs control-related
modifications in this regard, the original state must be restored when the
auxiliary device is removed.
1.2.23 Cleaning of machine and disposal

• Caustic substances, or substances harmful to human health or to the
environment (such as chlorinated carbohydrates of the types
perchloroethylene and trichloroethylene and similar) must not be used.
A conventional cold cleaner is recommended for cleaning the machine.
W
Important
There is a risk of dirt and cleaning products getting into the guides and seals.
For this reason, on no account should steam-cleaners, water-jets and
compressed air be used to clean the machine. These may impair proper
operation or functions, in particular safety functions, limit switches or
measuring systems.
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Environmental note
The cleaning substances and materials must be properly handled and
disposed of.
Always observe the currently valid disposal regulations applicable for the
installation location of the machine.
MX_MC6_V1.9_07.09.15_ENG
©KM
1-70 Safety
1.3 Intervention or access points
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Risk from uncontrolled intervention or access to machine.
There is a risk of severe injury or even death as a result of uncontrolled access
to machine.
Observe the intervention and access points marked on the machine. It is
prohibited to use any other points for intervening in, or gaining access to the
machine.
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Warning!
The ejector opening is not an access opening for the mold area.
Access must be made only by opening the safety gates.
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Important
Platforms, ladders and landings
When platforms, ladders and landings are used, the relevant local safety
regulations must be observed.
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-71
1.4 Safety at the machine
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Risk due to missing of safety devices
Removing, bypassing and/or disabling safety devices can result in life-
threatening injuries and/or property damage and thus is not permitted.
The machine must only be operated if the safety devices are in a proper
operational state.
Check the installed safety devices at regular intervals according to the

requirements of the current accident prevention regulations and DIN EN 201.
Ensure that these regulations are observed and that only authorized persons are
able to start the system or work at the system.
Operating, servicing and maintenance work must only be carried out by persons
who have been qualified for the particular task. The owner/operator of the
machine is responsible for training this group of persons, as well as for instructing
them in the regulations relating to Health and Safety at Work.
The safety devices of the injection molding machine consist of the following:
• Emergency-stop devices,
• Fixed protective panelling,
• Mechanical closing protection (ZE),
• Pressure limiting valve for pressure accumulator (ZE),
• Safety strips, safety gate (auxiliary device), power operated,
• Movable protective panelling (safety gates) with position switch,
• Chip card (ZE).
The position of the safety devices is shown in Fig. 1.1.

Each time before starting the machine, it is essential for the personnel to ensure
that proper safety at the machine is assured.
If malfunctions and/or deficiencies are discovered on the safety devices, the
machine must not be put into service or operation must be interrupted
immediately and qualified personnel notified.
If necessary, notify KraussMaffei Service (see section 0.10, page 0-36).
MX_MC6_V1.9_07.09.15_ENG
1.4.1.1 Notes
©KM
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Chip card
Only personnel authorized by the owner/operator may use the chip card.
Always remove the chip card when the activities are completed. Do not keep
the chip card at the machine.
1-72 Safety
• The protective panelling at the injection molding machine are safety devices
and must not be removed, modified or taken out of operation if the machine
is to be used in conformity with the specifications.
Limit switches must not be bypassed or rendered ineffective.
• If one of the safety gates at the operator side or operator rearside is opened,
all the machine movements are immediately interrupted or cannot be started.
• The "Mold opening" function is not possible if a safety gate is open on the
operator side. Opening the safety gate on the operator rearside switches the
machine to EMERGENCY STOP.
• If a safety gate is open, the "Mold closing" function is electrically and
hydraulically blocked.
• If a nozzle safety gate or a safety gate is open, the following functions are
blocked:
– "Injection unit forward",
– "Injection",
– "Plasticizing".
If the machine is equipped with a nozzle shut-off nozzle, the operation of the
shut-off nozzle is likewise blocked.
• If one of the safety gates is opened during the "Mold closing" function, the
movement of the machine is immediately interrupted in all operating modes.
The safety gates on the operator rearside switch off the pump motor and,
depending on the machine equipment, also the peripherals.
• Check the safety devices at regular intervals.
• Ensure that the fixed protective panelling is securely installed, particularly
after carrying out maintenance and service operations.
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Risk from hydraulic system
When rectifying faults or when carrying out maintenance work, it is important
to remember that, on the machine which is switched off electrically, parts of the
hydraulic system (e.g. clamping unit, hydraulic block) may still be pressurized
to a high pressure.
Before commencing work on the hydraulic system, check the pressures at the
test connections provided - in accordance with the hydraulic diagram.
Screw connections or plugs must not be opened until after ensuring that the
system or subsectors of the system are depressurized.
MX_MC6_V1.9_07.09.15_ENG
• Observe the tightening torques of the electrical connections and the

©KM
mechanical screw connections (see section 3.6, page 3-161) or when

opening assemblies/components (see chapter 18 Supplier Documentation)
during the following procedures:
– installing and connecting machine,
– commissioning machine,
– replacing assemblies, components,
– working on the electrical equipment.
Safety 1-73
1.4.2 Positioning of safety devices
1 2 3 4 5 6 7 8
45
20 19 18 17 16 15 14 13 12 11 10 9
21 22 23 24 25 26 27 30 31 32 33 41 42 34 40
35
36
28 37
47 29
38
39
46
45 21 22 43 44 43 30 34
Fig. 1.1 Safety devices KM 850 MX to KM 4000 MX
MX_MC6_V1.9_07.09.15_ENG
©KM
1-74 Safety
1 Ejector area safety gate 1) 25 Limit switch -B165, clamp safety circuit 2)
2 Limit switch -B1600, safety gate open, ejector area 1) 26 Safety gate mold area 2)
3 Limit switch -B151, open safety gate slowly 1) 27 Step-on safety grid (KM 1600 MX and earlier, only 2 limit
4 Safety gate mold area 1) switches) 2) 3)
5 Fault signal lamp 28 Step-on safety grid limit switch 2) 3)
6 Fixed protective panelling 1) 29 Limit switch, step-on safety grid, mold area 3)
7 Limit switch -B401, safety gate closed, nozzle area 1) 30 Door stop at the safety gate 1) 2)
8 Movable protective panelling, nozzle area 1) 31 Limit switch -B162, safety gate closed 2)
9 Master switch 32 Limit switch -B1630, service gate closed 2)
10 Safety strip -BW168, safety gate 1) 33 Limit switch -B1620, service gate open 2)
11 Limit switch -B160, safety gate closed, mold area 1) 34 Emergency-stop button (4x)
12 Limit switch -B164, close safety gate slowly 1) 35 Service gate 2)
13 Locking bolt 36 Valve clamp safety circuit -F166 2) 4)
14 Limit switch -B168, clamp safety circuit 1) 37 Valves -F103, -F110, dynamic clamp safety circuit 2) 5)
15 Limit switch -B161, safety gate open, mold area 1) 38 Protective panelling nozzle area 2)
16 Limit switch -B270, lock the locking bolts 1) 39 Limit switch -B402, safety gate closed, nozzle area 2)
17 Limit switch -B150, safety gate open 1) 40 Shut-off valve S5800 pressure accumulator, ZE 2)
18 Limit switch -B1610, safety gate closed, ejector area 1) 41 Safety gate acknowledgement button, outer -S16 (-S1625 6)) 2)
19 Limit switch -B1511, open safety gate slowly 1) 42 Acknowledgement button, inner -S1626 2) 6)
20 Limit switch -B1501, safety gate open 1) 43 Limit switch step-on safety grid 6)
21 Door stop at the MP 1) 2) 44 Step-on safety grid (KM 1600 MX and earlier, only 2 limit
22 Limit switch -B000, monitoring closing protection, ZE 1) 2) switches) 1) 6)
23 Step-on safety grid, mold area 3) (KM 1600 MX and earlier, only 45 Acknowledgement button, outer -S1620 1) 6)
4 limit switches) 46 Acknowledgement button, inner -S1621 1) 6)
24 Limit switch -B163, safety gate open, mold area 2) 47 Emergency-stop button, ejector area 6)
1) Operator side
2) Operator rearside
3) Starting from KM 1000
4) with safety switch -B166
5) with safety switches -B103 and -B110
6) only Brazil
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-75
1.4.3 Positioning of information and warning signs
1 2 3 4 5 6 7 8 9 10 11 12
12
3 4 21 20 17 19 18 17 12 16 15 14 13 10
22 18 17 12 22 12
10
22 22
Fig. 1.2 Positioning of information and warning signs (see fig. 1.3, page 1-77) and (see fig. 1.4,
page 1-78)
1 Minimum mold height 12 Load stop points (8x)
2 Extinguishing with water is forbidden (4x) 13 Master switch
3 Wear protective gloves 14 Type plate control cabinet
4 Hot surface 15 Electrical voltage (4x)
5 Heat up plasticizing unit before screw movement 16 Type plate injection molding machine
6 Type plate plasticizing unit 17 Risk of spraying
7 Drain the oil/prefill pressure in the pressure accumulator system 18 Wear protective helmet with face mask
8 Prefill pressure, pressure accumulator 19 Observe the operating manual (2x)
9 Maximum pressure, pressure accumulator 20 Risk of crushing (2x)
10 Bleed before commissioning 21 Hang both mold halves on the crane
MX_MC6_V1.9_07.09.15_ENG
11 Tank filling only via filter 22 Entry prohibited (5x)

©KM
1-76 Safety
1 Minimum mold installation 2 Extinguishing with water is

height (example)1) forbidden
3 Wear protective gloves 4 Hot surface
5 Heat up plasticizing unit 6 Type plate plasticizing unit

before screw movement
7 Drain the oil/prefill pressure in 8 Prefill pressure, pressure

the pressure accumulator accumulator
system
9 Maximum pressure, pressure 10 Vent at the Minimess

accumulator connection before
commissioning!
11 Tank filling only via filter 12 Load attachment points
< 5 µm
Fig. 1.3 Information plates (1/2)

1) The actual minimum mold installation height (see section 3.2, page 3-131)
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-77
13 Master switch 14 Type plate control cabinet
15 Electrical voltage 16 Type plate injection molding

machine
17 Risk of spraying 18 Wear protective helmet with

face mask
19 Observe the operating manual 20 Crushing hazard
21 Hang both mold halves on the 22 Entry prohibited

crane
Fig. 1.4 Information plates (2/2)
MX_MC6_V1.9_07.09.15_ENG
©KM
1-78 Safety
1.4.4 Alarm messages
6 2
3
4
Fig. 1.5 Alarm overview

1 "Alarm description" notes field 4 Information field
2 "Acknowledge" button 5 "Alarm overview" softkey
3 Alarm hardkey pressed 6 "Back to original screen" button
If an alarm is triggered, the red error signalling lamp flashes (see section 1.4.7,
page 1-83) on the machine.
The alarm hardkey flashes red on the screen of the operating/display panel.
1) Press the alarm hardkey.

The "Alarm overview" screen (see fig. 1.5, page 1-79) opens.
MX_MC6_V1.9_07.09.15_ENG
2) To display exact information in an expanded detail view, press the line of the
corresponding alarm.
©KM
A notes field (1, fig. 1.5), in which the cause of the alarm and options for
rectifying it are described in detail, opens under the line pressed.
Safety 1-79
3) Eliminate the cause of the alarm.
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Important
The control system constantly checks the alarm messages and deactivates the
drives if a red alarm message is found.
In manual, semi-automatic and fully automatic mode, the drives cannot be
activated as long as a red alarm message is present.
After an alarm has been acknowledged, the drives can be activated for 5
minutes (only in setting mode) in order to move the machine via the machine
operating buttons.
4) Acknowledge the alarm. To do so, press the "Acknowledge" (2, fig. 1.5)
button.
The alarm message is acknowledged and goes out, provided the fault has
been successfully rectified.
If the fault is not successfully rectified, the machine remains in the alarm
status.
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Important
For customized alarm messages, a reference to the cause of the fault appears
in the information field (4).
Refer to the information on rectifying faults in the relevant customized
documentation (see chapter 18 Supplier Documentation).
5) Press the "Back to original screen" button (6).

The previously displayed screen, from which the alarm hardkey was pressed,
is displayed again.
MX_MC6_V1.9_07.09.15_ENG
©KM
1-80 Safety
1.4.5 Emergency-stop button

Emergency-stop buttons, identified in red, are installed at the machine.
The buttons are installed:
• at the operating/display panel (operator side)
• in the mold cavity close to the fixed mold platen
• close to the service door (operator rearside)
• where applicable, on auxiliary devices (ZE)
If an emergency-stop button is operated, all the machine movements are

immediately stopped, the pump motor is switched off and the pressure
accumulator (if fitted) is discharged.
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Warning!
The emergency-stop button stops the movements of the machine.
• The machine is not de-energized when the emergency-stop button is
pressed.
• The barrel heating is not switched off.
• The auxiliary devices are only switched off if they are integrated in the
emergency-stop circuit.
• Once the emergency-stop button has been unlocked, dangerous
movements must be prevented using electrical safety equipment when
devices connected to sockets of the peripherals/interfaces of the machine
are restarted.
Observe these areas when performing further work.
The alarm A00901 "EMERGENCY STOP" is shown at the monitor and the fault
signal lamp is lit.
For safety reasons the buttons remain locked in the emergency-stop position.
In order to start the pump motor after EMERGENCY STOP button has been
pressed, this has to be unlocked and the alarm acknowledged.
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-81
1.4.6 Acknowledgement button
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Hazard
Before acknowledging the safety gates, operating and maintenance personnel
must ensure that there are no persons in the danger zone.
1 2
Fig. 1.6 Acknowledgement button

1 EMERGENCY STOP button 2 Acknowledgement button -S16
The acknowledgement button -S16 (2, fig. 1.6) is on the operator rearside of the
machine near the mold area safety gate.
When the mold area is exited, it must be enabled with the acknowledgement
button. Only then will a new cycle start be possible.
MX_MC6_V1.9_07.09.15_ENG
©KM
1-82 Safety
1.4.7 Fault signal lamps
1.4.7.1 Fault signal lamp
Fig. 1.7 Fault signal lamp (monocolour)

1 Signal buzzer 2 Lamp
If an alarm is triggered, the fault signal lamp lights up.

It goes out after the cause of the alarm has been rectified.
I
Note
In setting mode, the fault signal lamp is deactivated.
Acoustic fault signal (signal buzzer)

In automatic mode, an acoustic warning signal (signal buzzer) sounds in the case
of shutdown alarms in addition to the optical signal lamp.
The acoustic fault message can be switched off at the control system
(see section 8.17.2, page 8-674).
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-83
1.4.7.2 Extended fault signal lamp
Fig. 1.8 Extended fault signal lamp (three colours)

1 Signal buzzer 2 Lamps
The extended (three colours) fault signal lamp indicates the different operating
statuses.
The colour statuses mean the following:
• green = machine in production
• yellow = machine in setting mode
• red = machine fault
If an alarm is triggered, the fault signal lamp lights up red.

After elimination of the cause of the alarm, the fault signal lamp lights up green or
yellow depending on the operating status.
Acoustic fault signal (signal buzzer)

In automatic mode, an acoustic warning signal (signal buzzer) sounds in the case
of shutdown alarms in addition to the optical signal lamp.
The acoustic fault message can be switched off at the control system
MuCell
The extended fault signal lamp is a prerequisite for work with MuCell.
MX_MC6_V1.9_07.09.15_ENG
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©KM
Caution
When the orange lamp is lit or flashing, proceed with increased caution and
introduce appropriate safety precautions!
The orange lamp of the fault signal lamp:

• lights up when active back-pressure is switched on.
• flashes when active back-pressure is switched on and a safety gate is
opened.
1-84 Safety
1.4.8 Master switch
Fig. 1.9 Master switch in position I (ON)

1 Lock mechanism 3 Toggle switch
2 "Move out lock mechanism" button
For securing the master switch with a padlock, the lock mechanism (1, fig. 1.9)
must be moved out by pressing the "Move out lock mechanism" button (2).
I
Note
The master switch must only be locked with a padlock with a shackle diameter
of 7.5 mm to 9 mm.
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-85
1.4.9 Protective panelling

The protective panelling consists of movable protective panelling (safety gates)
for the mold, nozzle, ejector/core-pulling area, and of fixed protective panelling
(safety panels) for areas of the machine which represent a critical safety factor.
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Danger of crushing
The safe distances as per DIN EN ISO 13857 must be observed.
1.4.9.1 Protective panelling, mold area

The protective panelling of the mold area prevents access to this area during mold
movement, thus preventing a risk of crushing.
• The protective panelling of mold area is designed as follows:
– Fixed protective panelling and stop angle brackets at the movable mold
clamping platen,
– Safety gates at the operator side and operator rearside.
• The signals from the safety gate limit switches (operator side) as well as from
the safety gate (operator rearside) and the signal from the safety switch -
BH102 at the valve -FH102 (clamp safety circuit) are checked for their
logically reliable status on a time basis and forwarded to the pump control
circuit.
• When a safety gate is opened, the valve -FH102 (closing stroke safety) is
activated via the limit switches on the operator side or operator rearside and
the hydraulic pressure is blocked for any mold movement.
A message is displayed in the information field, indicating which safety gate
is open.
• A safety-gate-related alarm (A00902–A00912) is generated if the logically
safe status does not exist, and the movements at the injection molding
machine are immediately interrupted.
• After the fault has been rectified, the alarm messages are acknowledged by
pressing the alarm hardkey and the "Acknowledge" button on the screen. MX_MC6_V1.9_07.09.15_ENG
©KM
1-86 Safety
1.4.9.2 Protective panelling nozzle area

The nozzle safety gates provide the protection from points at which limbs may
suffer contusions or even be sheared off as a result of the movements of the
injection unit. In addition, safety gates protect the operator from any plasticized
injection melt which flows out and from parts thrown out of the nozzle area.
The nozzle safety gates are each monitored by means of a limit switch. If a gate
is opened, step P00021 "Nozzle guard open" is displayed and the cycle is
interrupted. The "Injection unit forward", "Injection" and "Plasticizing" functions
are blocked. The cycle is automatically continued after the nozzle safety gate is
closed.
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If a safety gate is open, it is possible for injection melt which is still plasticized
to flow out of the nozzle.
Risk of scalding on heated components of the machine.
Wear your personal protective equipment and prevent unauthorized access of
third persons.
1.4.9.3 Screw barrel protective panelling

Fixed protective panelling is installed over the heater bands of the screw barrel.
The protective panelling protects against unintentional contact with the heating
bands or the barrel.
1.4.9.4 Protective panelling ejector area

The ejector area is protected as standard with a fixed protective panelling on the
operator rearside and with a safety gate on the operator side.
The safety gate is monitored by a limit switch. If the gate is open, alarm A00902
"Ejector gate open" is displayed and the pump motor is switched off.
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Risk of burning on hot materials.
Wear personal protective equipment.
MX_MC6_V1.9_07.09.15_ENG
©KM
Safety 1-87
1.4.10 Securing the work area
1.4.10.1 Service gate (safety gate core-pulling/clamping block)

Access to the core-pulling/clamping block at the FP is protected by a service gate.
If the gate is open, alarm A00904 "Service gate open" is displayed and the pump
motor is switched off.
1.4.10.2 Step-on safety grid (as of KM 1000 MX)

The mold area on the operator rearside is monitored by a step-on safety grid.
If any person steps into the mold area, one or several limit switches is operated
which interrupts the power supply to the control valves. The "Safety gate closing"
and "Mold closing" functions are interrupted or are not carried out. Step P00076
"Step-on safety grid actuated" is displayed.
1.4.10.3 Safety strip, safety gate mold area

A vertical safety strip is positioned at the safety gate to the mold area.
If the safety strip is activated, either the closing movement of the safety gate is
interrupted or the movement cannot be started.
Step P00154 "Safety gate safety strip actuated" is displayed.
1.4.10.4 Locking bolt (as of KM 1000 MX)

See "Open/close safety gate (ZE)" (see section 6.6.1, page 6-274).
Close safety gate

In the following two cases, a locking bolt prevents unintentional closing of the
hydraulic safety gate for the mold area (see section 6.6.10, page 6-285):
• One mold area safety gate is opened.
• One EMERGENCY-STOP button was actuated.
In these cases, the safety gate cannot be closed and step display P00124
"Locking bolt safety gate: moved out" is shown.
1.4.10.5 Clamp safety circuit

The clamp safety circuit prevents mold closing movements when the safety gate
is open.
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1-88 Safety
1.4.10.6 Door stop
1 2
Fig. 1.10 Door stop

1 Door stop bolts at the MP (marked red) 3 Door stop bolts at the safety gate (marked red)
2 Door stops 4 Mold area safety gate on operator side
The machine is delivered with door stops installed on the operator side and
operator rearside. The door stops limit the maximum safety gate opening to
prevent manual intervention in the ejector area.
When installing the automation for the lateral demolding, the door stop must be
removed in order to fully open the safety gate for robot intervention.
If a robot is no longer used for lateral demolding, the door stops must be
reinstalled to re-establish safe machine status.
Removal/installation of door stops

1) Unscrew the red marked bolts at the door stops (see fig. 1.10, page 1-89).
2) Remove door stops.
3) Keep door stops in safekeeping for reinstallation.
4) Installation of the door stops is carried out in reverse order.
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Safety 1-89
1.4.10.7 Robot work area
5
4 2
Fig. 1.11 Robot work area

1 Safety gate 4 Safety switch with integrated door detection
2 Actuator unit with door handle (silver grip) sensor
3 Emergency release with handle (red grip) 5 Safety gate acknowledgement button
(= U+ P1 - S106)
I
Note
• The arrangement applies to all depositing versions.
• See also "Technical documentation for linear robot".
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1-90 Safety
1.4.10.8 Interface robot housing door, robot/injection molding machine according to

EUROMAP 73
Via this interface, when the housing door for the robot is opened the mold
movements and the ejector/core movements are blocked with the machine safety
gate open (operator side/operator rearside).
Interface description (see section 11.2, page 11-796).
I
Note
With installed keyswitch -S016 with foot switch (ZE X89.08) in setting/manual
mode:
• With manual mold removal on the operator rearside of the injection molding
machine, the function of keyswitch -S016 is deactivated (no ejector/core
movements possible with open machine safety gate on operator rearside).
• With manual mold removal on the operator side of the injection molding
machine, ejector/more movements are possible with the machine safety
gate open on the operator side.
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Safety 1-91
1.5 Inspection of safety devices

On accepting the machine, the owner/operator assumes responsibility for the
completeness and function of the safety devices.
The safety devices must be inspected at regular intervals and this has to be
documented.
An additional inspection is required in the following cases:

• after installing and connecting machine
• when mold changed
• if the safety gates have been closed for a lengthy period of time
• after maintenance and repair work.
If deficiencies are discovered on the safety devices, the machine must be shut
down immediately. All deficiencies must be rectified before the machine is put
back into service.
W
Important
Foreign parts (removed gates, frozen melt, loose parts etc.) may adversely
affect the safety functions or deactivate them.
Before each machine start-up, an inspection must be carried out to ensure that
there are no foreign parts in the machine. If any foreign parts are found, they
must be removed from the machine.
Inspection of the safety devices depends on the equipment of the machine and
consists of the following:
• Inspection of emergency-stop buttons

• Inspecting the safety gates, mold area (operator side and operator rearside)
• Inspecting the locking bolt monitor (from KM 1000 MX)
• Inspecting the safety strip
• Inspecting the service gate
• Inspection of the safety gate, nozzle area
• Inspecting the safety gate, ejector area
• Inspecting the step-on safety grid (as of KM 1000 MX)
MX_MC6_V1.9_07.09.15_ENG
• Inspecting the clamp safety circuit

• Inspection of fixed protective panelling
©KM
• Inspecting the robot safety gates (ZE)
1-92 Safety
1.5.1 Inspection of the EMERGENCY-STOP buttons and the EMERGENCY-STOP

circuit
Prerequisites
• Machine functional
• Semi- and fully automatic mode pressure accumulator loaded
• All interfaces with EMERGENCY STOP (e.g. robot, GID, protective fence)
disconnected for inspection
Procedure
1) Switch on pump motor and heaters.
2) Select mode of operation.

3) Press emergency-stop button at the operating/display panel until it latches.
• All machine movement must be stopped immediately.
• The software blocks all machine movements for one minute.
• The pump motor switches off.
The pump motor function button turns blue.
• Current supply for the solenoid valves switches off.
• Alarm A00901 "EMERGENCY STOP" is displayed.
• Fault signal lamp must light up in manual/semi-automatic/fully automatic
mode.
• Pressure accumulator must discharge.
• The barrel and mold heating remain switched on.
• The auxiliary devices are only switched off if they are integrated in the
emergency-stop circuit.
• The yellow service socket in the control cabinet is not disconnected from
the power supply.
4) Unlock emergency-stop button.
5) Acknowledge the alarm.
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6) Switch pump motor on.

7) Perform steps 2 to 6 for each emergency-stop button:
• in the operating/display panel (operator side)
• in the mold cavity close to the fixed mold platen
• close to the service door (operator rearside)
• where applicable, on auxiliary devices (ZE)
Safety 1-93
1.5.2 Inspecting the mold area safety gates (operator side and operator
rearside)
1) Check that the limit switch and wiring are firmly installed and that the shift
levers and rollers are in good condition and easy to move.
2) Select setting mode.
4) Open the safety gate of the mold area, operator side, until limit switch -B160
(11, fig. 1.1) is no longer actuated.
5) Hold down the limit switch -B160 by hand for approx. 3 seconds.
• Alarm A00910 "Operating gate limit switch" is displayed.
• Fault signal lamp is illuminated.
I
Note
An alarm of the safety gates (operator side/operator rearside) or of the clamp
safety circuit cannot be acknowledged until both safety gates have been
opened, one after the other, and closed again.
W
Important
With a power-driven safety gate, the "opening" and "closing" movement of the
safety gate is carried out with an alarm bypass. The alarm bypass is
deactivated automatically.

8) Close the safety gate again.
9) Hold down the limit switch -B168 (14, fig. 1.1) by hand for approx. 3 seconds.
• Alarm A00911 "Limit switch, closing stroke safety/operating gate" is
displayed.
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10) Acknowledge the alarm
12) Hold down the limit switch -B161 for approx. 3 seconds.
• Alarm A00910 "Operating gate limit switch" is displayed.
1-94 Safety

15) Carry out work steps 3 to 14 for the limit switches of the mold area safety gate,
operator rearside (-B162, -B165, -B163).
Instead of the alarm A00910 "Operating gate limit switch", the alarm A00907
"Operator rearside gate limit switch" is displayed.
I
Note
Opening and closing the operator rearside mold area safety gate must be
acknowledged by pressing the acknowledgement button next to the door.
If the operator rearside is opened and closed again, then you can acknowledge
at any time.
If both gates have been opened, the operator rearside can only be
acknowledged if the operator side is still open.
Otherwise, the acknowledgement is not carried out. Step P00665 "Safety gate
not acknowledged" is displayed.
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Safety 1-95
1.5.3 Inspection of locking bolt monitoring

2) Switch on pump motor and heating.

3) Open the safety gate without actuating limit switch -B270 (16, fig. 1.1).
4) Initiate closing safety gate.
• Safety gate must not close.
• Step P00124 "Locking bolt safety gate: moved out" is displayed.
5) Close safety gate by hand.
• Alarm A00069 "Locking-bolt monitoring" is displayed.
• Heater must not shut off.
6) Open safety gate until limit switch -B270 is activated.
7) Close safety gate by hand.
• Alarm A00069 "Locking-bolt monitoring" is displayed.
• Heater must not shut off.
1.5.4 Inspecting the safety strip

1) Initiate "Close safety gate".
2) During the closing movement, hit the safety strip -BW168 (10, fig. 1.1) with
the edge of your hand.
• The closing movement is interrupted immediately.
• Step P00154 "Safety gate safety strip actuated" is displayed.
• The pump motor is not switched off.
MX_MC6_V1.9_07.09.15_ENG
• When the safety gate strip is activated, it must be possible to open the
gate using the "Open safety gate" button.
©KM
3) Carry out the check at various heights of the safety gate strips.
1-96 Safety
1.5.5 Inspecting the service gate (core-pulling and clamping block)

3) Open the service gate.
• Alarm A00904 "Service gate open" is displayed.
4) With the service gate open, press and hold down limit switch -B1600
(33, fig. 1.1) or -B1630 (32, fig. 1.1) for 3 s.
Alarm A00908 "Service gate limit switch" is displayed in addition to alarm
A00904 "Service gate open".
I
Note
The alarm A00908 "Limit switch, service gate" can only be acknowledged if the
service gate is closed and, in addition, the ejector gate is opened and closed.
5) Close the service gate.


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Safety 1-97
1.5.6 Inspecting the nozzle area safety gate

2) Switch on pump motor and heating.

3) Open the nozzle area safety gate (operator side).
4) Press the "Injection unit forward" button.

• It must not be possible to start the "Injection unit forward" function.
• Step P00021 "Nozzle guard open" is displayed.
• The "Injection unit back" function is not blocked.
5) Initiate "Injection" function.
• No injection takes place.
6) Initiate "Plasticizing" function.
• No plasticizing takes place.
7) Repeat work steps 1 to 6 Wed nozzle safety gate operator rearside (limit
switch -B402; 39, Fig. 1.1).
8) Close the safety gate again.
The "Injection unit forward" function can be started again.
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1-98 Safety
1.5.7 Inspecting the ejector area safety gate

3) Open the ejector gate.
• Alarm A00902 "Ejector gate open" is displayed.
4) With the ejector gate open, press and hold down limit switch -B1600 or
-B1610 (2, Fig. 1.1 and 18, Fig. 1.1) for 3 s.
Alarm A00909 Ejector gate limit switch" is displayed in addition to alarm
A00902 "Ejector gate open".
I
Note
Alarm A00909 "Ejector gate limit switch" can only be acknowledged if the
ejector gate is closed and, in addition, the service gate is opened and closed.
5) Close the ejector gate again.


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Safety 1-99
1.5.8 Checking the step-on safety grid

3) Open the safety gates to the mold area.
4) Inspect the switching distances of the limit switches to the step-on safety
grids.
Step-on safety grids must operate the switching rods of the limit switches at
least halfway.
5) With an open operator side safety gate (operator rearside safety gate closed),
place weight of not more than 20 kg on the corner of the step-on safety grid.
• Step P00076 "Step-on safety grid actuated" is displayed.
7) With the operator side safety gate open (operator rearside safety gate
closed), set the max. weight of 50 kg to the middle of the step-on safety grid.
9) Carry out steps 5 to 8 for each operator side step-on safety grid.
10) Carry out the same checks on the operator rearside (safety gate on operator
side remains closed).
11) Open safety gate on operator rearside, place weight on step-on safety grid,
close safety gate.
12) Acknowledge the operator rearside safety gate.
13) Initiate mold closing.
• It is not possible to initiate any mold movement.
W
Important
In the case of split step-on safety grids, conduct a check for each section.
14) After completing the checks, remove the weight again.

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1-100 Safety
1.5.9 Inspecting the clamp safety circuit
W
Important
This check must only be carried out for the commissioning and as part of an
inspection.

2) Open the mold area safety gate on the operator rearside.
3) Disconnect connector -B166 from closing stroke safety valve -F166
(36, fig. 1.1).
The alarms A00911 "Limit switch, clamp safety circuit/operator gate" and
A00912 "Limit switch, clamp safety circuit" are displayed.
4) Insert connector -B166 at clamp safety circuit valve -F166 (36, fig. 1.1).
5) Close the mold area safety gate on the operator rearside and perform
acknowledgement.
6) In the switching functions, switch on "Ignore alarms in setting mode" function.
8) Open the mold area safety gate on the operator side.
9) Actuate the locking bolt.
10) Close the mold area safety gate on the operator side.
I
Note
The alarm A00912 "Limit switch, closing stroke safety" cannot be
acknowledged until both safety gates are opened, one after the other, and
closed again.
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Safety 1-101
1.5.10 Check of dynamic clamp safety circuit
W
Important
This check must only be carried out for the commissioning and as part of an
inspection.

2) With safety gates on operator side and operator rearside closed, remove
connector -B103 from valve -F103 (37, fig. 1.1) on hydraulic block.
3) Select "Semi-automatic or fully automatic mode".
4) Press button "Start machine cycle" to initiate cycle.

• After the end of the cycle, alarm A00004 "Clamp safety circuit" is
displayed.

7) With safety gates on operator side and operator rearside closed, remove
connector -B110 from valve -F110 (37, fig. 1.1) on hydraulic block.
8) Select "Semi-automatic or fully automatic mode".
9) Press button "Start machine cycle" to initiate cycle.
• After the end of the cycle, alarm A00004 "Clamp safety circuit" is
displayed.
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1-102 Safety
1.5.11 Inspection of fixed protective panelling

1) Inspect the elements of the fixed protective panelling to ensure they are
complete and not damaged. Replace any missing or defective parts.
2) Inspect the parts and the elements attaching them (e.g. rivets, bolts, hinges,
clips) to ensure that they are present and tight. Properly attach any loose parts
and replace any missing attaching elements.
3) Check that the safety elements (e.g. bolt locks, pinnings) are present and
fulfilling their purpose, and replace them if necessary.
1.5.12 Inspecting the robot safety gates (ZE)

1) Check the secure seating of the safety switch, the actuator unit and the
emergency release (4, 2 and 3, Fig. 1.11).
2) Select setting mode at the robot.
3) Open the safety gate (1, fig. 1.11).
4) Deselect setting mode at the robot.
"Robot safety gate open" step display.
5) Close the safety gate.
Integrated door detection sensor is actuated.
6) Lock the door handle of the actuator unit (2, fig. 1.11).
The safety switch is actuated (4, fig. 1.11).
7) Acknowledge the safety gate with the acknowledgement button on the
protective panelling (5, fig. 1.11).
8) Deselect setting mode at the robot.
• "Stop" step display.
• "Home position" button flashes.
9) Functional check of emergency release (3, fig. 1.11):
Within the danger zone, it must be possible to open the guard devices; it must
not be possible to lock the guard devices from the inside.
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Safety 1-103
1.6 Pressure accumulator

The pressure accumulator is subject to the pressure equipment directive
97⁄23⁄EC.
W
Important
For operation, the workplace safety regulations or the corresponding national
regulations must be observed.
Before the pressure accumulator system is commissioned, it must be
inspected by an inspector at the instigation of the owner/operator. For the
arrangement of inspection periods, the owner/operator must carry out a
technical safety evaluation.
If a modification is made to the operating method, the connections or the

equipment, a qualified person must check that installation at the operating
location conforms with specifications and regulations.
1 2 3
Fig. 1.12 Pressure accumulator valve block

1 Pressure gauge at pressure accumulator (S580) 3 Drain cock S5800 (manual release to the tank)
2 Pressure switch BP581 (blocking from/to the system)
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w
D
Warning!
©KM
Before commencing maintenance work at the pressure accumulator, ensure

that the master switch of the machine is switched off and is secured from being
switched on again.
1-104 Safety
The connections and valves are all located within the soundproof pump room
booth on the operator rearside or on a separate accumulator unit close to the
soundproof pump room booth.
• Disconnect pressure accumulator from the system for maintenance work. To
do this, unplug connector BP581 (2, fig. 1.12) from pressure switch.
• After this, release pressure accumulator by manually actuating drain
cock S5800 (3, fig. 1.12) towards the tank.
• After opening drain cock S5800, check that no pressure is indicated on
pressure indicator S580 (1).
The pressure accumulator is protected against hydraulic overloads by means of

the pressure limiting valve F5800.
W
Important
The pressure limiting valve F5800 is a safety valve and is always provided with
an anti-tamper seal (from the relevant inspection authority). If this seal is
destroyed or missing, it is then necessary to immediately install a new valve
tested by the relevant inspection authority and fitted with an anti-tamper seal.
The new valve must be provided with the appropriate acceptance test
certificates.
Keep the certificates supplied with the machine (see chapter
19 Reports/Certificates) in the machine documentation and present them to
the relevant inspector when the repeat inspection is performed.
If the pressure accumulator is subject to a pressure of ≤ 225 bar, it must be loaded

until a pressure of 235 bar maximum is reached.
The pressure accumulator is discharged when the following functions are

triggered:
• Emergency-stop function
• Switch-off alarms
• Switching off pump motor
• Change of mode of operation, semi-automatic/fully automatic mode 
manual/setting mode
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Safety 1-105
1.7 Hydraulic hose lines

Service life and storage life
h
d
D
Risk from hydraulic or pneumatic systems
The use of hydraulic hose lines with an expired service life or storage life can
result in injury to persons and failure of the machine.
• The hydraulic hose lines are based on DIN 20066.
According to this, the reference value for the
– service life including the storage life is maximum 6 years.
– Storage life of hydraulic hose lines is maximum 2 years.
• Inspect the hose lines for damage and for the service life.
• After the initial operating hours under production conditions, it is necessary
to have the pipe and hose connections inspected by an expert for defects
and have any defects present eliminated by taking suitable measures.
• After this, an expert must inspect the pipe and hose connections at least
once a year to ensure that they are in reliable operating condition.
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1-106 Safety
1.8 Safety test/safety instruction

Prior to commencing work, the knowledge of the operating personnel must be
tested by a competent person (e.g. Superior, Safety Officer).
This inspection must be repeated every six months.
I herewith confirm that I have read and understood the "Safety" chapter in full.
Date Name First name Department Signature

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Safety 1-107
MX_MC6_V1.9_07.09.15_ENG
©KM
1-108 Safety
2 Fundamentals of Injection Molding Technology

This chapter provides you with fundamental information regarding the design and
function of the machine.
2.1 Injection molding machines . . . . . . . . . . . . . . . . . . . 110
2.2 Plasticizing (3-zone screw) . . . . . . . . . . . . . . . . . . . 113
2.3 Wear-intensive plastics and additives . . . . . . . . . . 116
2.4 Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.5 Injection molding . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.6 Two-component injection molding technology . . . 124

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Fundamentals of Injection Molding Technology 2-109

2.1 Injection molding machines

Injection molding machines are used to manufacture plastic molded parts of
different colours, shapes and sizes. Processing of thermosetting plastics involves
transforming the initial material in the machine into a plastic state by heating it,
then injecting it under pressure into a closed shape (mold) and removing it from
the mold after a cooling phase.
2.1.1 Structure
1 2 3 4 5
Fig. 2.1 Design of the MX injection molding machine

1 Ejector 4 Power and control cabinets
2 Clamping unit 5 Injection unit
3 Operating/display panel
2.1.2 Injection unit MX
1 2 3 4 5 6 7
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Fig. 2.2 Design of the injection unit (SP 12000)

1 Guide 5 Injection unit housing
2 Thermal jacket 6 Guide carriage
3 Screw barrel 7 Drive motor
4 Screw mount
2-110 Fundamentals of Injection Molding Technology

Function
• Homogeneously melting the material
• Mixing material
• Transporting material
• Injecting material in mold cavity
2.1.3 Injection units - combination options
Injection unit A (main injection unit) 1) Injection unit B (Z-position)
Injection unit C (V-position) Injection unit D (L-position)
Injection unit E (H-position) Injection unit F (W-position)

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Fig. 2.3 Injection units - combination options

1) Element of this manual
Designation of the injection units (see section 3.1, page 3-130).

2.1.4 Clamping unit MX

Function
• Supporting mold
• Opening and closing mold
• Closing mold against injection pressure
Design of MX clamping unit
1 2 3 4
Fig. 2.4 Design of MX clamping unit

1 Hydraulic middle ejector 3 Column
2 Movable mold platen (MP) 4 Fixed mold clamping platen (FP)
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2.2 Plasticizing (3-zone screw)
2.2.1 Structure
1 2 3
Fig. 2.5 Diagram of the 3-zone screw

1 Ejection zone 3 Feed zone
2 Compression zone
1 2 3 4 5
Fig. 2.6 Design of a plasticizing unit

1 Screw tab 4 Barrel wall
2 Return-flow lock 5 Filling opening
3 Screw
2.2.2 Function
The material which runs through the filling opening (5, fig. 2.6) is transported by
the rotating screw (3).
On the way forwards, the turning of the screw brings the material into contact with
the hot cylinder wall (4). In addition, the rotation (shearing in the molding material)
generates additional heat (frictional heat).
The mold mass which is transported into the screw tab (1) pushes the screw
further and further back as the screw tab increasingly fills until the set plasticizing
stroke is achieved.
The plasticized mold mass can then be injected with the screw (no longer rotates,
MX_MC6_V1.9_07.09.15_ENG
and now acts as a piston) into the shaping cavity of the mold.
The return-flow lock (2) at the end of the screw prevents the melt flowing back into
©KM
the screw channels.

While the mass is cooling down in the mold, it is then possible to begin with the
plasticizing of the mass for the mixed injection shot.
Special features
A high temperature-resistant plasticizing unit should be provided for processing
high temperature-resistant materials.

2.2.3 Screw types

Standard screw
Universal screw for processing a wide range of materials. If this type of screw is
used, it is not always possible to achieve optimum performance although the
screw satisfies demands in the majority of cases.
Mixing screw
For mixing in (mechanically homogenising) dye pigments, as well as powder
granulate as well as paste-like direct processing of several components.
In other words, homogenising materials of different viscosities and molecular
weight distributions.
Recommended where particularly high demands are made in respect of the
mechanical and thermal homogeneity of the mold mass.
Special screws
PVC Thermoset plastics Elastomer plastics
Special screws allow for the particular thermal, rheological and tribological
properties of specific materials.
Venting screws
Processing of all hygroscopic mold masses which, for optical or technological
reasons, have to be dried prior to processing, in particular, though, also of
hygroscopic regenerates.
High-performance screws
High-performance screws are used when the highest requirements are set with
regard to throughput, melting performance and homogeneity.
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2.2.4 Metering
The volume required for the injection molded part is determined by trial metering,
in which the mold is first of all filled to less than capacity.
After the mold has been completely filled incl. holding pressure time a small melt
cushion must remain.
If the processing temperature and/or times are changed, please note that this
may also possibly change the metering.
Changes to a calculated metering setting may adversely affect the quality of the
final part, e.g. stress crack performance.
It is good practice to carry out a check of the weight of the molded part in
harmonization with the other processing parameters.
The plasticizing time is determined by

• injected volume,
• type of plastic,
• screw speed and geometry
• back-pressure.
2.2.5 Screw advance speed

The screw advance speed influences the temperature distribution in the mold. As
the speed increases, the melt temperature in the mold rises, which in turn ensures
that the mold is filled with an amorphous melt (improved temperature and
pressure balance).
With the exception of unfavourable local areas in the molded part, the flow front
speed in the mold cavity stabilizes in accordance with the geometry of the molded
part in proportion to the screw advance speed.
The aim of having a high flow front speed conflicts with the requirement for a
relatively slow swell filling (low screw advance speed) for achieving good surfaces
on the molded part.
Priority must be given to the quality requirement even if a compromise solution is
occasionally unavoidable depending on the geometry of the molded part and the
gate ratios.
At higher screw advance speeds, shrinkage variations and thus the tendency to
distort are largely reduced.
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2.3 Wear-intensive plastics and additives
Plastics Additives
Polyamide (PA) Glass (fibre and balls)
Polycarbonate (PC) Natural calcium carbonates (chalks, limestone, marble)
Polyoxmethylene (POM) Natural silicas (sand, crystal)
Acrylonitrile butadiene styrene (ABS) Metal oxides (titanium, chrome oxides)
Polyvinyl chloride (PVC) Talcum
Styrene acrylonitrile (SAN) Ceramic
Polybutene therephthalate (PBTP) Asbestos
Polyphenylene oxide (PPO) Metal powder
Polysulphone (PSU) Flame protection
2.3.1 Abbreviations of names of plastics

Abbreviations for names of plastics as per DIN EN ISO 1043-1. See the DIN
standard sheets for information on proper use of the abbreviations in the
literature. In some instances (particularly in US documentation) when mentioning
the abbreviations of the names of polymerisates, P = poly is omitted, e.g. TFE
resins or only TFE in place of PTFE.
MX_MC6_V1.9_07.09.15_ENG
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2.4 Mold temperatures
Plastics Mold temperature [°C]

PS, SB, SAN, ABS 10-80
PE 20-60
PP 20-80
PVC 20-60
PA6 60-100
PA6.6, 6.10 40-90
PA12 40-80
PC 80-120
CA, CP, CAB 40-80
PMMA 40-80
POM 40-120
PU 40-80
Polyester 170-200
Alkyd resins 160-180
Phenolic resins 170-190
Urea resins 130-150
Melamine phenolic resins 170-190
Predrying of plastics
Plastics Predrying time [h] Predrying temperature [°C]

PS 1-3 60-80
ABS 24 70-80
CA 2 70-80
PMMA 24 70-100
PA 24 80-100
PC 24 100-120
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2.5 Injection molding
2.5.1 Basic principles of injection molding

Optimal quality of the molded part is achieved by good interaction of
• machine,
• mold,
• material,
• operating conditions.
A high-performance injection molding machine with sophisticated control is not

able to supply its optimum if
• the mold is incorrectly designed,
• the mold temperature cannot be exactly controlled,
• the mold does not match the machine (e.g. plasticizing),
• an incorrect material has been selected,
• the material is not correctly processed (e.g. predrying).
It is important to take into account various points in respect of the mold, such as
• shrinkage and demolding skews,
• temperature control (heat-balancing channel and hotrunner design),
• design of sprue and gate,
• Machine size.
Even with the best material you will not achieve a satisfactory result if
• the machine does not offer all the necessary setting facilities,
• the machine is not set correctly,
• the mold is not designed for the specific material,
• the screw geometry selection was not made material-specifically.
Operating conditions
• The shop temperature must be constant (no draughts).
• Use optimized cooling devices and heat-balancing units.
• Use parts removal unit cycles to obtain uniform cycles.
2.5.2 Sequence of the injection molding process

MX_MC6_V1.9_07.09.15_ENG
The process times are shown in the figure "Injection molding cycle" (see fig. 2.7,
page 2-119).
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The pourable material passes from the material filling hole into the cooled material
feed zone of the screw barrel, the so-called SC hopper (cooling prevents clotting
in the feed zone).
The rotating screw conveys, compresses and plasticizes the mold melt, which is
metered by means of the set plasticizing stroke.

During the mold filling process the screw injects the plastic melt under pressure
(injection pressure) and at a speed (injection speed) into the closed, cold or
temperature-regulated mold. During this process the screw (usually) does not
rotate.
The melt in the mold shrinks as a result of the transition from the liquid-plastic into
the solid state and as a result of cooling down.
To compensate for this contraction in volume which would result in the formation
of shrink holes and sink marks, the screw advances further as a result of the
holding pressure, and pushes the melt further into the mold.
After the set holding pressure time has elapsed, the new plasticizing operation
can be started parallel to the commencement of the cooling time. This takes place
at the set screw RPM and with a pressure which acts on the screw moving back
(back-pressure).
Screw RPM and back-pressure depend on the material used.
In addition, in the majority of cases, the screw is moved back after plasticizing
without rotating in order to relieve the pressure on the melt in the screw tip.
At the end of the set cooling time, the mold is opened and the molded part can be
removed (by hand or with a part removal device) or ejected. The new cycle
commences with mold closing.
Injection molding cycle
1
2
3
8
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Fig. 2.7 Injection molding cycle

1 Mold closing (t1) 5 Cooling (t5)
2 Injection unit forward (t2) 6 Injection unit back (t6)
3 Injection molding (t3) 7 Transporting (t7)
4 Holding pressure (t4) 8 Mold open (t8)

Fig. 2.8 Overview of times

1 Cycle time actual value 2 Reference time
2.5.3 Injection pressures (injection, holding and back pressure)

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A close correlation exists between the pressure curve in the mold and the quality
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of the molded part. In the figure entitled "Influence of pressure curve on mold
quality" (see fig. 2.9, page 2-121), several quality characteristics have been
assigned to the areas of the pressure curve, which primarily influence the
pressure curve.
The filling phase (injection) is responsible to a considerable extent for the surface
layer and for the mechanical and thermal stress of the melt resulting from
shearing.

The filling phase, though, also defines the temperature distribution in the melt at
the commencement of the holding pressure. This temperature distribution
influences the entire pressure curve and all the quality characteristics which are
linked to it.
The holding pressure results in a compression of the melt and therefore primarily
determines those quality characteristics which are dependent
• on the density and
• on the spec. volume, e.g.
– weight,
– sink points,
– shrinkage and
– distortion.
The holding pressure should be set only high enough that it is adequate to avoid
shrink holes and sink points. Experience has shown that a higher holding
pressure is required for partially crystalline plastics than for amorphous plastics.
7
2
8
6
5 4 3
Fig. 2.9 Influence of pressure curve on mold quality

1 Filling point (F1) 5 Injection time (t1)
2 Max. pressure (PW1) 6 Quality of surface layer 1)
3 Holding pressure time (t3) 7 Proper shaping of contours 2)
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4 Compression time (t2) 8 Compression along the flow path 3)

1) Thermal and mechanical stress of melt
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2) Filling, completeness, proper shaping of contours, fins, flashing.

3) Bubbles, sink marks, weight, shrinkage, distortion, degree of crystallization, orientation in interior, demolding speeds.

2.5.4 Energy-efficient operation

Additional information is provided below as suggestions for energy and resource-
saving operation.
2.5.4.1 Machine, mold, peripherals

• Always utilize the injection molding machine to the greatest extent possible in
terms of shot weight for efficient operation (see section 8.13.3.1,
page 8-610).
• Shut off unnecessary additional features and peripherals (such as a dryer or
suction conveyor) when not in use (see chapter 12 Auxiliary devices).
• Equip the machine with full plasticizing barrel insulation if possible
(see section 8.10, page 8-531).
• Equip molds in use with heat insulation boards, particularly in the <15°C
and >50°C range (see section 2.4, page 2-117).
• Keep the hose lengths for mold heat-balancing as short as possible to
minimize flow resistance.
• Avoid peripherals operated by energy-inefficient compressed air if possible or
make sure they are implemented optimally (see section 10.11, page 10-746).
2.5.4.2 Machine setting

• Switch off the machine's drives and heating during pauses/idle phases
(see section 6.4, page 6-268).
• Always configure just the amount of clamping force actually required and
configure harmonic closing/opening movement without intermediate stops
and quick speed changes (see section 8.7.1, page 8-413).
• Always select the smallest possible opening width for the clamping unit
• Only set the nozzle contact force to the value required for production
(see section 8.9.3.1, page 8-502).
• When lifting out the nozzle do not move back farther than needed
(see section 8.9.3.1, page 8-502).
• Select the nozzle at the injection barrel with as wide a cross-section as
possible (see section 10.12.6, page 10-764).
• Orient the barrel temperatures as close to the lower limits for the processing
guidelines of the respective plastic (see section 8.10, page 8-531).
• Configure the injection molding process to be optimal in terms of energy
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(see section 2.5.1, page 2-118), including choosing the lowest possible
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holding pressure time and quantity, always minimizing the cooling time,
keeping back pressure at the lowest possible level at all times.

2.5.4.3 Production planning

Do the following to optimize energy efficiency:
• Minimize setup times
• Avoid or optimize changes for colours or repairs if possible
• Preheat molds outside the machine if possible
I
Note
A visit to a relevant seminar is recommended for more in-depth information with
regard to energy efficiency for production planning as well as the machine's
settings and functions (see chapter 0.8 Training).
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2.6 Two-component injection molding technology
2.6.1 Basic procedural sequence for 2K-injection molding
1 The mold is opened.

2 Plasticizing unit is running.
3 The mold is closed. Any available cores move in.

4 The first component A is injected.
5 Holding pressure and cooling phases take place.
6 Further cavities are opened, e.g. through rotation

technology or sliding technology (core-pulling technology).
7 The second component 2K is injected.
8 Holding pressure and cooling phases take place.

9 The mold opens.
10 The 2K-component is demolded.
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Fig. 2.10 2K-injection molding - procedural sequence

2.6.2 2K-injection molding procedures

2K-injection molding procedures are often referred to under the collective terms
"multiple-colour injection molding" and "multiple-component injection molding".
The plastic materials and molded part functions used in the application are
decisive for distinguishing between the procedures.
2.6.2.1 Distinguishing between procedures
Distinction according to material combination
Multiple-colour injection molding Multiple-component injection molding

Plastic materials of the same type with Different plastic types are joined.
different colouring are joined.
Distinction according to process
Compound injection molding Sandwich injection molding

The plastic materials are injected onto or over The plastic materials are injected into one
one another. another.
Both components are injected via different Both components are injected via the same
sprue positions. sprue.
The second component is injected after the Melt-melt contact takes place during injection
pre-injection molded part has cooled down (hot border surface).
(cold border area).
(see section 2.6.2.2, page 2-126) (see section 2.6.2.3, page 2-128)
Special processes are also available, e.g.:

• Multiple-component injection process
• Back injection molding or insert molding of semi-manufactured articles
Further distinguishing features

There are other distinguishing features, e.g.:
• Mold technology (transfer technology/sliding technology/rotation technology)
• Material pairing (hard/soft, hard/hard, thermoplast/elastomer)
• Connection type (positive fitting, material bonding, jointed)
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2.6.2.2 Compound injection molding
Fig. 2.11 Compound injection molding – process
1 2
Fig. 2.12 Compound injection molding – molds

1 Injecting onto each other 2 Injecting over each other
Injecting onto each other

Injecting onto each other is used, for example, to attach a soft lip to a hard carrier
part. Here, the carrier is injected on first and then the lip. The connection can be
physical/chemical or mechanical.
Injecting over each other

When injecting over each other, a basic molded part is obtained from the first
material, which is then partially or completely injected over with the second plastic
or is covered over with it. The connection of both plastics can be
physical/chemical or mechanical here too. Intentional "non-compound" is
achieved using two plastics, which have no tendency to form compounds (known
as installation injection molding).
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Distinguishing according to mold technology
Rotation technology Transfer technology Sliding technology

Rotation of parts of the mold: Prior to injection of the second Before injection of the second
• Vertical: with rotary table component, the pre-injection molded component, the locking slides or cores
(1, fig. 2.13), turrets, rotary part is inserted or relocated manually or open up the rest of the cavity
cores, index plates by the handling device. (see fig. 2.14, page 2-127).
• Horizontal: rotation of middle
mold part by means of a turning
board (2) or cube
Fig. 2.13 Compound injection molding – rotation technology

1 With rotary table 2 With turning board
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Fig. 2.14 Compound injection molding – sliding technology

2.6.2.3 Sandwich injection molding
Fig. 2.15 Sandwich injection molding – process
Fig. 2.16 Sandwich injection molding – mold
The articles in the core consist of a certain plastic (e.g. recyclate), wrapped in an
outer skin made of a different plastic. The type and colour of the plastics can be
the same or different. Only the two-channel plate is adapted to the conventional
mold for the sandwich. The procedure begins with the skin material and then, after
a simultaneity phase, complete filling is achieved with the core components. A
small amount of skin material is injected afterwards for gate sealing.
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3 Specifications
I
Note
This chapter contains general machine specifications and information
concerning the machine environment. Current and order-related machine data
can be found in the provided documents of the parts lists/drawings and
diagrams (on CD, if applicable).
The dimensions and weights specified here relate only to the injection molding
machine. If the machine is equipped with auxiliary devices such as a robot
(see chapter 12 Auxiliary devices) or other peripherals (see chapter
18 Supplier Documentation), the dimensions are increased accordingly and,
where applicable, can be obtained in the other technical documentation
(possibly on CD).
3.1 Designation of the injection units . . . . . . . . . . . . . . 130
3.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.3 Requirements for the installation location,

complete machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.4 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.5 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.6 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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Specifications 3-129
3.1 Designation of the injection units

The letters specified below appear wherever reference is made to the respective
injection unit or rotary unit.
Injection units
The following letters have been defined to designate the injection units:
Designation Injection unit Position

A Main injection unit horizontal
B 2nd injection unit mounted on A, inclined (Z-position)
C 2nd injection unit vertical on fixed mold platen (V-position)
D 2nd injection unit (Bolt-on) horizontal at right angles, operator rearside (L-position)
E 2nd injection unit horizontal parallel to A (next to A)
F 2nd injection unit horizontal opposite A, on movable mold platen
Additional designations for injection units (assemblies) and their modes of

operation:
Designation Injection unit / mode of operation

1-component 1st injection unit / main injection unit
injection unit
1-component mode 1-component mode (operation with one injector, without rotary/sliding tables)
2-component 2nd injection unit for multi-injection unit operation
injection unit
2-component mode 2-component mode (operation with at least two injectors, with one/two rotary/sliding tables if applicable)
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3-130 Specifications
3.2 Machine data

Injection molding machine KM 850 MX
Clamping unit
Clamping force [kN] 8500
Mold opening force [kN] 560
Mold clamping platen (h x v) [mm] 1600 x 1600
Clear width between columns (h x v) [mm] 1140 x 1140
Mold opening stroke [mm] 1600
Mold installation height min./max. [mm] 500 - 1100
Opening width [mm] 2100
Ejector stroke [mm] 300
Ejector force forward/back [kN] 200⁄100
Injection unit SP 4300
Screw diameter [mm] 80 90 100
LS⁄D ratio 23 20 18
Injection pressure [bar] 2328 1839 1490
Swept volume [cm3 ] 1810 2290 2827
Shot weight PS [g] 1647 2084 2573
Injection speed [mm⁄s] 100
Injection flow [cm3 ⁄s] 503 636 785
Working capacity 1) 4212
Screw speed [rpm] 228
Plasticizing flow PS at screw speed [g⁄s] 124 157 194
Installed heating capacity [kW] 41
Control zones, barrel heating 7
Nozzle contact force [kN] 129
Electrohydraulic equipment
Pump motor rated output [kW] 90
Dry cycle runtime/stroke (Euromap 6) 2) [s / mm] 3.8 / 798
Oil filling [l] 1500
Dimensions and weights
Net weight [t] 41.5
Length x width x height (without machine mounting) [m] 10.28 x 2.92 x 2.57
Max. mold weight [kg] 12200
MACHINE OPTIONS 3)
Increased mold installation height
Increased injection speed
Injection flow [cm3 ⁄s] 1508 1909 2356
Electric screw drive
Screw drive power [kW] 71
Electric screw drive, amplified
1) [cm3]
International designation of quantity calculated from max. swept volume x max. injection pressure [bar] divided by 1000
2) Dry cycle runtime according to EUROMAP 6: stroke = 70% of horizontal clear width, clamping force = 70%
MX_MC6_V1.9_07.09.15_ENG
3)
Partly deviating technical data, dimensions and Weight
©KM

Clamping unit
Clear width (h x v) [mm] 1140 x 1140
Injection unit SP 6100 SP 8100 SP 12000
Screw diameter [mm] 85 95 105 95 105 115 105 120 135
Injection pressure [bar] 2242 1795 1469 2173 1778 1483 2296 1758 1389
Swept volume [cm3] 2695 3367 4113 3721 4546 5453 5195 6786 8588
Shot weight, HDPE [g] 1914 2391 2920 2642 3228 3872 3689 4818 6098
Injection speed [mm⁄s] 97 93 99
Injection flow [cm3⁄s] 553 690 843 659 805 966 856 1117 1414
Working capacity 1) 6042 8085 11928
Screw speed [rpm] 146 150 144
Plasticizing flow HDPE at screw speed [g⁄s] 76 102 132 105 135 171 130 183 249
Installed heating capacity [kW] 47 54 59 54 59 64 75 86 97
Control zones, barrel heating 7 7 7
Nozzle contact force [kN] 166 166 166
Pump motor rated output [kW] 90 110 132
Dry cycle runtime/stroke (Euromap 6) 2) [s / mm] 3.8 / 798 3.8 / 798 3.8 / 798
Oil filling [l] 1500 1500 2440
Net weight [t] 43 43.5 49
Length x width x height (without machine mounting) [m] 10.53 x 2.92 x 2.57 10.81 x 2.92 x 2.57 11.72 x 2.93 x 2.71
Max. mold weight [kg] 12200 12200 12200
MACHINE OPTIONS 3)
Screw drive power [kW] 109 129 145
1) International designation of quantity calculated from max. swept volume [cm3] x max. injection pressure [bar] divided by 1000
3) Partly deviating technical data, dimensions and Weight
MX_MC6_V1.9_07.09.15_ENG
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Clamping unit
Injection unit SP 4300 SP 6100
Screw diameter [mm] 80 90 100 85 95 105
LS⁄D ratio 23 20 18 23
Injection pressure [bar] 2328 1839 1490 2242 1795 1469
Swept volume [cm3 ] 1810 2290 2827 2695 3367 4113
Shot weight PS [g] 1647 2084 2573 - - -
Shot weight, HDPE [g] - - - 1914 2391 2920
Injection speed [mm⁄s] 100 97
Injection flow [cm3 ⁄s] 503 636 785 553 690 843
Working capacity 1) 4212 6042
Screw speed [rpm] 228 146
Plasticizing flow PS at screw speed [g⁄s] 124 157 194 - - -
Plasticizing flow HDPE at screw speed [g⁄s] - - - 76 102 132
Installed heating capacity [kW] 41 47 54 59
Control zones, barrel heating 7 7
Nozzle contact force [kN] 129 166
Pump motor rated output [kW] 90 90
Dry cycle runtime/stroke (Euromap 6) 2) [s / mm] 4.4 / 994 4.4 / 994
Oil filling [l] 1500 1500
Net weight [t] 50 51.5
Length x width x height (without machine mounting) [m] 10.70 x 3.42 x 2.61 10.95 x 3.42 x 2.61
Max. mold weight [kg] 20300 20300
MACHINE OPTIONS 3)
Screw drive power [kW] 71 109
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Clamping unit
Ejector force forward/back [kN] 200/100
Swept volume [cm3] 3721 4546 5453 5195 6786 8588 7634 9662 11928
Oil filling [l] 1500 2440 2400
Net weight [t] 52 57.5 61.5
MACHINE OPTIONS 3)
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Clamping unit
LS⁄D ratio 23 20 18 23
Swept volume [cm3 ] 1810 2290 2827 2695 3367 4113
Shot weight PS [g] 1647 2084 2573 - - -
Shot weight, HDPE [g] - - - 1914 2391 2920
Installed heating capacity [kW] 41 47 54 59
Net weight [t] 59 60,5
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 3721 4546 5453 5195 6786 8588 7634 9662 11928
Oil filling [l] 1500 2440 2400
Net weight [t] 61 67 71
MACHINE OPTIONS 3)
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Clamping unit
LS⁄D ratio 23 23
Swept volume [cm3 ] 2695 3367 4113 3721 4546 5453
Shot weight, HDPE [g] 1914 2391 2920 2642 3228 3872
Plasticizing flow HDPE at screw speed [g⁄s] 76 102 132 105 135 171
Installed heating capacity [kW] 47 54 59 54 59 64
Dry cycle runtime/stroke (Euromap 6) 2) [s / mm] 5,1 / 1099 4,9 / 1099
Net weight [t] 63.5 64
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 5195 6786 8588 7634 9662 11928 10735 13254 16037
Control zones, barrel heating 7 7 7 7 8
Dry cycle runtime/stroke (Euromap 6) 2) [s / mm] 4,6 / 1099 4,6 / 1099 4,6 / 1099
Oil filling [l] 2440 2400 3200
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3 ] 2695 3367 4113 3721 4546 5453 5195 6786 8588
Injection flow [cm3 ⁄s] 553 690 843 659 805 966 856 1117 1414
Oil filling [l] 1500 1500 2440
Net weight [t] 77,5 78 83
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 7634 9662 11928 10735 13254 16037 14577 17438 21652
Control zones, barrel heating 7 7 7 8 8 8 9
Oil filling [l] 2400 3200 6200
MACHINE OPTIONS 3)
Injection flow [cm3⁄s] 1527 1932 2386 1861 2297 2780
Second pump unit for increased drive output
Injection flow [cm3⁄s] 2405 2877 3572
MX_MC6_V1.9_07.09.15_ENG
Plasticizing flow HDPE at screw speed [g⁄s] 297 377 500

1) 3
International designation of quantity calculated from max. swept volume [cm ] x max. injection pressure [bar] divided by 1000
©KM

Clamping unit
LS⁄D ratio 23 23
Swept volume [cm3 ] 3721 4546 5453 5195 6786 8588
Dry cycle runtime/stroke (Euromap 6) 2) [s / mm] 8,1 / 1309 7,4 / 1309
Net weight [t] 102 107
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 7634 9662 11928 10735 13254 16037 14577 17438 21652
Oil filling [l] 2400 3200 6200
Net weight [t] 111 115 138
MACHINE OPTIONS 3)
MX_MC6_V1.9_07.09.15_ENG
3)
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Clamping unit
Swept volume [cm3 ] 3721 4546 5453 5195 6786 8588 7634 9662 11928
Oil filling [l] 1500 2440 2400
Net weight [t] 116 121 125
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 10735 13254 16037 14577 17438 21652 23655 29046 33452
Oil filling [l] 3200 6200 6650
Net weight [t] 129 150 156
MACHINE OPTIONS 3)
MX_MC6_V1.9_07.09.15_ENG
3)
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Clamping unit
LS⁄D ratio 23 23
Swept volume [cm3 ] 5195 6786 8588 7634 9662 11928
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 10735 13254 16037 14577 17438 21652 23655 29046 33452
Oil filling [l] 3200 6200 6650
Net weight [t] 155 176 182
MACHINE OPTIONS 3)
MX_MC6_V1.9_07.09.15_ENG
3)
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Clamping unit
LS⁄D ratio 23 23
Swept volume [cm3 ] 7634 9662 11928 10735 13254 16037
Control zones, barrel heating 7 7 7 8
MACHINE OPTIONS 3)
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Clamping unit
Swept volume [cm3] 14577 17438 21652 23655 29046 33452 35216 40301 45729
Oil filling [l] 6200 6650 7450
Net weight [t] 211 217 225
MACHINE OPTIONS 3)
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Clamping unit
LS⁄D ratio 23 23
Swept volume [cm3 ] 7634 9662 11928 10735 13254 16037
Control zones, barrel heating 7 7 7 8
MACHINE OPTIONS 3)
MX_MC6_V1.9_07.09.15_ENG
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Clamping unit
Swept volume [cm3] 14577 17438 21652 23655 29046 33452 35216 40301 45729
Oil filling [l] 6200 6650 7450
Net weight [t] 246 252 260
MACHINE OPTIONS 3)
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3.3 Requirements for the installation location, complete machine
3.3.1 Ambient conditions for the electrical equipment

• Ambient temperature for open electrical equipment (provided that the
average air temperature does not exceed +35°C within a 24 h period):
+5°C up to +40°C, at a constant shop temperature
• Ambient temperature for closed electrical equipment (provided that the
average air temperature does not exceed +50°C within a 24 h period):
+5°C up to +50°C, at a constant shop temperature
• Electrical connected ratings and fuse protection:
– Type plate on control cabinet
– Circuit diagram (see chapter 16 Electrical system).
3.3.2 Air specification

• Air humidity: Relative air humidity from 30 % up to 95 % (no formation of dew)
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3.4 Operating materials
3.4.1 Water specification
W
Important
Poor water quality leads to increased susceptibility to corrosion and reduces
cooling performance (e. g. by clogging the cooling ducts).
I
Note
• This water specification only applies to machine cooling and mold cooling
via water manifold.
• This water specification applies to the mold cooling with no restrictions in
machines that have a rotary table with hose feedthrough.
• In machines that have a rotary table with rotary feedthrough, the water has
to be additionally prepared specifically for mold cooling (see section 3.4.2,
page 3-154).
• On machines with electric screw drive, the special requirements of the
drive manufacturer must be observed.
The requirements of the specification (see fig. 3.1, page 3-153) must be met by
the owner/operator of the machine.
W
Important
Avoid the following:
• Soiling and sludging,
• Calcification (in the cooler among other areas),
• Accelerated growth of micro-organisms due to high water temperatures,
• Microbiological decay,
• Corrosion (observe electrochemical voltage series in, among other things,
systems and components).
• We recommend using drinking water without additives for maintenance-free

MX_MC6_V1.9_07.09.15_ENG
operation.
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• For ambient temperatures < 0 °C, add antifreeze to cooling water.

• There must be no aggressive substances in the medium.
• Additives are only permitted if they have a neutral response to the operating
elements used.
• The following are required:
– the use of filters or dirt traps (nominal mesh width < 160-250 µm).
– inspections (water analyses) or regular decalcification.
• Corrosion protection agents may have to be used. Clarify the use of these
agents with KraussMaffei beforehand.
W
Important
If the concentration is in the problem zone, there must not be several
assessment characteristics in it at the same time. Extreme caution must be
taken when several problematic substances are present because the entire
result can then come into the impermissible zone.
Assessment characteristic Concentration zone/Assessment

permitted problematic impermissible
Appearance clear, without sediment
Colour colourless to yellowish
Odour none
pH value 6- 8.5 < 6, > 8.5 < 5, > 10
Electrical conductivity, 25 °C [µS/cm] < 1500 > 1500 > 2500
Chloride [mg/l] up to 200 200- 300 > 350
Sulphate [mg/l] up to 65 65- 90 > 90
Nitrate [mg/l] up to 55 55- 65 > 65
Free carbonic acid, aggressive [mg/l] up to 20 20- 45 > 45
Sum of alkaline earths, Ca, Mg [mMol/l] up to 4 >4
Acid capacity K s 4.3 1) [mMol/l] up to 6.5 > 6.5
Oxygen [mg/l] up to 2 >2
Ammonium [mg/l] up to 2 2-5 >5
Iron, dissolved [mg/l] up to 0.2 0.2 - 0.5 > 0.5
Manganese, dissolved [mg/l] up to 0.05 0.05 - 0.1 > 0.1
Chlorine, free [mg/l] up to 5 >5
Salt content [mg/l] 1000 > 1000 > 1700
Ammonia impermissible
Sulphide impermissible
German hardness [°dH] 6 to 18 > 18 > 20
Total hardness (TH)
Carbonate hardness 2) [°dH] up to 12 > 12 > 18
Colony forming units 1/ml 3) [CFU] up to 1000
Legionella 1/ml [CFU] up to 10
Water inlet temperature
• Standard [°C] 5-31 > 31 > 31
• with reinforced oil cooler [°C] 5-36 > 36 > 36
Max. water pressure [bar] 6
MX_MC6_V1.9_07.09.15_ENG
Fig. 3.1 Reference values for fresh water, drinking water

1)
up to pH 4.3 when using hardness stabilizers; water treatment products can increase the Ks 4.3 value, thus simulating carbon hardness;
©KM
2) when using hardness stabilizers

3) in the event of value increase: perform germ reductions
I
Note
• The carbonate hardness is expressed by converting the hydrogen
carbonates into the corresponding quantity of calcium oxide (CaO).
1°dH = 10 mg/l CaO
• Correlation:
1000 µS/cm = approx. 700 mg salt
• Water analyses as per DIN 50930
3.4.2 Hydraulic oil
3.4.2.1 Hydraulic fluid, specification
W
Important
In order to ensure proper operation of the hydraulic system, as well as to avoid
any failures of hydraulic components as a result of sludging, only hydraulic oils
of Class HLP 46 must be used.
Characteristic data for HLP oils as per DIN 51524-2
Characteristic data Unit HLP oils Test procedure

Viscosity class 46 DIN 51519
Kinematic viscosity DIN 51562-1
• at 40 °C [mm2⁄s] 46
• at 100 °C [mm2⁄s] 6.9
Density at 15 °C [kg⁄m3] 875 DIN EN ISO 12185
Flash point (as per Cleveland o.T.) [°C] > 220 DIN ISO 2592
Pourpoint [°C] -27 DIN ISO 3016
FZG-test (breakdown-load stage) 12 DIN 51354-2
Air separation ability LAV at 50 °C [min] <6 DIN 51381, ISO 9120
Water content [%] < 0.05 DIN 51777
Neutralization value of fresh oil [mg KOH⁄g] < 0.5 DIN 51558-1
Increase in the neutralization value compared to fresh [mg KOH⁄g] < 1.5 DIN 51587
oil after 1000 h (delta NV)
Oxide ash [%] < 0.2 EN 7
MX_MC6_V1.9_07.09.15_ENG
Water pollution class 1-2

©KM
I
Note
If the machine is being operated with servo pumps, the tank temperature can
fall below the permissible minimum value due to the low application of energy
to the oil so that it may be necessary to use the following oil:
Mobil DTE 10 Excel 32.
However, this would first require a software update of the machine control
system by KraussMaffei Service Department.
Hydraulic oil requirement

What is meant by hydraulic oil is a mineral oil that meets the requirements as per
DIN 51524-2.
The additives added must not have any negative effects on the materials located
in the system.
• The thermal load rating of the hydraulic oils must be designed in such a way
that no negative effects occur at operating temperatures of up to 70 °C.
Recommended operating temperature (can be entered): 45 °C to 50 °C.
• High corrosion protection and compatibility with non-ferrous metals.
• Very good oxidation resistance.
• High temperature stability; no resinification or precipitation of crystalline
constituents.
• Use of primary raffinates for long service life.
• Filterability with 1 µm filter fineness must be guaranteed when using undiluted
oil.
• Neutralization value must be stable over the duration of operation
(increase < 1 compared to fresh oil).
Hydraulic oil quality

The hydraulic oil quality for operating the injection molding machine must not be
worse than the purity classes 17/14/10 as per ISO 4406.
The particle share can be further reduced through practical filtration, e.g. bypass
flow filtration (3 µm(c) to 5 µm(c) at Beta = 200).
In principle, mixing hydraulic oils must be avoided. Before switching to a different
make of oil, check that the residual oil and new oil are compatible and can be
mixed at 50 °C.
Zinc-stabilized and zinc-free oils must not be mixed.
The residual oil volume (one type) must be kept to a minimum, e.g. by flushing
the system with new oil.
t
i
Environmental note
Only certain sorts of hydraulic oil may be intermixed for disposal. Enquire at
manufacturer/supplier regarding disposal of the hydraulic oil used.
W
MX_MC6_V1.9_07.09.15_ENG
Important
©KM
Representative sampling or online counts must be carried out constantly to

check that the corresponding degree of purity is maintained.
3.4.2.2 Sampling
I
Note
Oil is at operating temperature (machine has run for at least 1 h).
The recommended sampling spot is on the hydraulic block at the Minimess
connection downline of the pump.
Proceed as follows when taking the oil sample:

1) With the pump running (full volume flow), screw in the Minimess hose and
allow a sufficient volume of liquid (approx. 2 l) to flow into a separate tank in
order to flush the Minimess hose and dead zones in the inlet area to the
Minimess connection.
The sample must never be taken from a valve that has just been opened and
is not flushed.
2) Unpack the sampling bottle.
I
Note
The sampling bottles must be cleaned and inspected in accordance with
ISO 3722.
Cleanness of less than 10 particles > 4 µm(c) and less than 2 particles >
6 µm(c) per millilitre bottle volume is sufficient.
3) Remove the screw cap from the sampling bottle and hold it in your free hand
without touching the inside surface of the screw cap.
4) Place the sampling bottle immediately under the liquid flow and fill at least
50% of the bottle and no more than 80%.
I
Note
If the bottle is too full, reduce to the prescribed oil volume immediately.
In order to prepare oil samples in the laboratory (homogenization), a volume of
at least 130 ml and a maximum of 200 ml is required (with 250 ml sampling
bottles).
MX_MC6_V1.9_07.09.15_ENG
5) Seal the bottle immediately with the screw cap before closing the sample
©KM
removal valve.
6) Label the sampling bottle unambiguously and permanently (e.g. with a self-
adhesive label).
7) Fill in the oil sampling data sheet. Answer the questions carefully.
8) Send the oil sample together with the data sheet to a laboratory for
determination of the degree of oil purity in accordance with ISO 4406.
i
t
Environmental note
The used hydraulic oil must be collected and disposed of in a suitable manner
for the environment and the surroundings.
Observe the corresponding national regulations for dealing with hydraulic oil.
3.4.3 Lubricant specification
W
Important
Do not mix lubricating greases with lubricating greases that have a different
soap base.
W
Important
Only certain sorts of lubricating grease may be intermixed for disposal.
Enquire at manufacturer/supplier regarding the requirements for disposing of
the lubricants used.
i
t
Environmental note
The used lubricating grease must be collected and disposed of in a suitable
manner for the environment and the surroundings.
Observe the corresponding national regulations for dealing with lubricating
greases.
MX_MC6_V1.9_07.09.15_ENG
©KM
3.4.3.1 Lubrication specification for sliding surfaces on injection unit
Grease characteristics for CASTROL TRIBOL® 4020/220-2
W
Important
• At higher temperatures (over +100 °C to + 150 °C), the relubrication
intervals must be adjusted carefully. Ensure that grease that fills the
bearings remains pliable.
• Quality standard: CASTROL TRIBOL® 4020 lubricating greases exceed
the minimum requirements for lubricating greases K as per DIN 51825.
Characteristic data for TRIBOL 4020/220-2 Unit Characteristic value Test procedure
Labelling as per DIN KP 2 N-30 DIN 51502
Consistency as per NLGI class 2 DIN 51818
Soap base Lithium complex
Worked penetration 265–295 0.1 mm DIN ISO 2137
Drip point [°C] > 240 DIN ISO 2176
Base oil viscosity DIN 51366
• at 40 °C [mm2⁄s] 220 ISO-VG 150 to 220
• at 100 °C [mm2⁄s] 19
Flash point [°C] 230 DIN ISO 2592
Oil separation, 40 °C/168 h [%] 2.5 DIN 51817
Behaviour towards water
• 90 °C, evaluation level 0 DIN 51807/1
Oxidation stability DIN 51808
• Pressure drop, 100 h at 99 °C < 250
• Pressure drop, 300 h at 99 °C < 400
Copper corrosion (100 °C) 24 h Degrees 1) 1 DIN 51811
Rust protection properties Degrees 1) 1 ASTM D 1743
Emcor test Degrees 1) 0/0 ISO 11007
Roll stability Change in % 10 ASTMD D 1831
VKA wear test DIN 51350-05-E
• Calotte diameter [mm] < 0.7
SRV test, 50 °C, 300 N, 2 h amplitude 1000 µm DIN E 51834-02-S
• Frequency 50 Hz [µm] 0.07-0.09
FAG-FE 9 test (1500/6000-150) 1) DIN 51821-02-A
MX_MC6_V1.9_07.09.15_ENG
Flow pressure at -20 °C [hPa] 850 DIN 51805

©KM
Operating temperature range [°C] -30/+150

1) passed
3.4.3.2 Lubrication specification, central lubrication system
Grease characteristics for CASTROL TRIBOL® 3020⁄1000-2
Characteristic data for TRIBOL Unit Characteristic Test procedure

3020⁄1000-2 value
Labelling as per KP 2 K-30 DIN 51502
Consistency as per NLGI class 2 DIN 51818
Soap base Lithium -
Worked penetration 0.1 mm 265-295 DIN ISO 2137
Drip point [°C]  180 DIN ISO 2176
Base oil properties
• Viscosity at +40 °C [mm2⁄s] 1000 DIN 51366
• Viscosity at +100 °C [mm2⁄s] 54 DIN 51366
• Flash point [°C] 230 DIN ISO 2592
Response to water, 90 °C
• Water pollution class 0 DIN 51807⁄1
Oxidation resistance DIN 51808
• Pressure drop, 100 h at 99 °C [hPa] < 300
• Pressure drop, 300 h at 99 °C [hPa] < 400
Copper corrosion (100 °C) 24 h Degrees 1 DIN 51811
Rust protection properties Degrees 1 ASTM D 1743
Emcor test Degrees 0⁄0 DIN 51802⁄IP 220⁄67
Roll stability Change in % 5 ASTM D 1831
Oil separation [%] 2.8 DIN 51817
Four-ball EP test DIN 51350⁄4
• Welding load [N] 4000⁄4200
Four-ball wear test DIN 51350-0, 5-E
• Calotte diameter [mm]  0,8
SRV test, 50 °C, 300 N, 2 h [µm] 0.070-0.085 DIN 51834-02-S
Amplitude 1000 µm, frequency 50 Hz
Flow pressure at 20 °C [hPa] 650 DIN 51805
FAG-FE 9 test DIN 51821-2⁄1500⁄6000⁄-120
Service temperature [°C] -30 to +120
MX_MC6_V1.9_07.09.15_ENG
©KM
3.4.3.3 Oil specification, electric screw drive
Characteristic data of gear oil CLP 114 (220) as per DIN 51502
Characteristic data for CLP 220 as per DIN 51502 Unit Characteristic value Test procedure
Viscosity class 220 ISO VG DIN 51519
Base oil Mineral oil
Density at 15 °C [kg/m3] 900 ISO 3675
Viscosity class ISO ISO/VG 220 DIN 51519
Viscosity at 40 °C [mm2⁄s] 220 DIN 51562
Viscosity at 100 °C [mm2⁄s] 19 DIN 51562
Pourpoint [°C] -21 ISO 3016
Temperature range [°C] -10 to +135
Flash point [°C] 250 ISO 2592
Colour brown
FZG test A/8.3/90 > 12 DIN 51354
3.5 Noise emission

The time-averaged sound pressure level conforming to EN ISO 3744 for the
MX series is 73 ± 2 dB(A) for machines not equipped with air valves.
w
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Caution
If machine is equipped with air valves: The specified noise level of the machine
may be considerably exceeded at times if blow-off devices or similar
equipment is fitted.
E
B
Hearing protection
Prevent any noise problems for the operating personnel by taking suitable
protective measures; for example, have the personnel wear ear protection in
the noise area.
MX_MC6_V1.9_07.09.15_ENG
©KM
3.6 Tightening torques
3.6.1 Securing bolts on hydraulic components, tightening torques
w
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Caution
Bolts which have been incorrectly tightened may produce hazardous
situations.
Do not use any insertion washers or lock washers; insertion washers or lock
washers falsify the tightening torque.
The surfaces between bolt head and contact surface which transmit the
tightening torque must be metallically blank and clean; otherwise, the
tightening torque will be falsified.
Bolt type: DIN EN ISO 4762 Tightening torque [Nm]

M5 8
M6 13
M8 31
M10 62
M12 110
M14 186
M16 270
M18 397
M20 530
W
Important
In case of deviation from order-related data:
• Observe binding tightening torques on assembly drawings.
• Assemble according to parts lists and assembly drawings.
MX_MC6_V1.9_07.09.15_ENG
©KM
3.6.2 Bolts in high-temperature area, tightening torques
W
Important
• Only bolt connections coated with Molykote paste type P74 must be
tightened on the plasticizing unit. The Molykote paste makes it possible to
slacken bolt connections that have been heated to very high temperatures
over a long period of time.
• The contact surfaces of the bolt head must be metallically blank and clean;
otherwise, the tightening torque will be falsified.
• If several bolts are arranged in a divided circle, the bolts must be tightened
evenly and in diagonally opposite sequence.
Standard bolt sizes
W
Important
Due to thermal stress, bolts in the high-temperature area >150 °C must be
tightened to a reduced torque.
Thread Property class Tightening torque Hexagon socket

[Nm] wrench size
[mm]
M4 2.9 3
M5 6.0 4
M6 10 5
M8 25 6
M10 49 8
M12 75 9
M16 10.9 210 14
M20 410 17
M24 710 19
M30 1400 22
M36 2400 27
M42 3900 32
M45x1.5 1000 32
MX_MC6_V1.9_07.09.15_ENG
©KM
I
Note
In the case of deviating tightening torques in the respective assembly
drawings, the values of the assembly drawing apply.
3.6.3 Bolts on barrel head, tightening torques
W
Important
• Only bolt connections coated with Molykote paste type P74 must be
tightened on the plasticizing unit. The Molykote paste makes it possible to
slacken bolt connections that have been heated to very high temperatures
over a long period of time.
• The contact surfaces of the bolt head must be metallically blank and clean;
otherwise, the tightening torque will be falsified.
• If several bolts are arranged in a divided circle, the bolts must be tightened
evenly and in diagonally opposite sequence.
3.6.3.1 Screw connection, SP 4300 MX to SP 17200 MX
Fig. 3.2 Screw connection, SP 4300 MX to SP 17200 MX

1 Quantity A of bolted connections
Screw barrel type Qty. A Bolt version DIN EN ISO 4762 Tightening torque [Nm]
SP 4300MX 20 Cylinder bolt M20x200/10.9 392
SP 6100MX 20 Cylinder bolt M24x250 680
SP 8100 MX 20 Cylinder bolt M24x250 680
SP 12000MX 18 Cylinder screw M30x280 1360
SP 17200MX 18 Cylinder screw M30x280 1360
MX_MC6_V1.9_07.09.15_ENG
©KM
3.6.3.2 Screw connection SP 24500 MX to SP 75000 MX
Fig. 3.3 Screw connection SP 24500 MX to SP 75000 MX

1 Quantity A of bolted connections
Screw barrel type Qty. A Bolt version DIN EN ISO 4762 Tightening torque [Nm]
SP 24500MX 15 Necked down bolt M42x236⁄48 CrMoV6.7 3600
SP 33000 MX 16 Necked down bolt M42x236⁄48 CrMoV6.7 3600
MX_MC6_V1.9_07.09.15_ENG
©KM
3.6.4 Tightening torques of securing bolts
Thread Property class Hexagon wrench size Hexagon socket wrench size
8.8 10.9 12.9 [mm] [mm]
Tightening torque [Nm]

M4 2.9 4.1 4.9 7 3
M5 6.0 8.5 10 8 4
M6 10 14 17 10 5
M8 25 35 41 13 6
M10 49 69 83 15/17 8
M12 86 120 145 19 9
M14 135 190 230 22 10
M16 210 295 355 24 14
M18 290 405 485 27 14
M20 410 580 690 30 17
M22 550 780 930 32 17
M24 710 1000 1200 36 19
M27 1050 1500 1800 41 19
M30 1450 2000 2400 46 22
M33 1900 2700 3250 50 24
M36 2450 3450 4150 55 27
M39 3200 4500 5400 60 30
M42 3950 5550 6650 65 32
M45 4950 6950 8350 70 32
M48 5950 8400 10100 75 36
M52 7650 10800 12900 80 41
M56 9550 13400 16100 85 41
M60 11900 16700 20000 90 46
MX_MC6_V1.9_07.09.15_ENG
©KM
MX_MC6_V1.9_07.09.15_ENG
©KM
4 Transport/Packaging
This chapter contains information about transport and packaging of the machine
series.
I
Note
For transport, packaging and handling, the "Transport, packaging and handling
guideline" from the General Terms and Conditions of KraussMaffei
Technologies (www.kraussmaffei.com/de/agb.html) shall apply.
National laws and specifications must also be observed.
4.1 Safety precautions for transportation . . . . . . . . . . . 168
4.2 Requirements regarding personnel operating

the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.3 Transport/lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.5 Sea transport of machines with shrinking foil

packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
MX_MC6_V1.9_07.09.15_ENG
©KM
Transport/Packaging 4-167
4.1 Safety precautions for transportation
l
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When transporting a load there is always the risk of it falling down.
Never stand or walk under raised loads.
Before transporting a load, compare the weight of the item and the load-bearing
capacity of the ropes and cranes as well as other auxiliary tackle and select a
means of transportation which offers sufficient safety and lifting capacity.
If using a crane for transport, secure the ropes on the crane hook to prevent the
load from capsizing because the centre of gravity of the load can be in an
eccentric position.
When transporting a load with a forklift, ensure that the forks have adequate load
bearing capacity and are the proper size. Adhere to the specified dimensions and
weights in the following tables (see section 4.3.1, page 4-170).
r
d
D
Risk of slipping
When transporting a load, service products such as hydraulic oil may flow out
and contaminate the area around the machine.
Drain the machine before transporting it and/or secure the service product
reservoirs to prevent any fluids from escaping.
Immediately clean up any escaped operating materials in an environmentally
responsible manner.
b
B
Wear personal protective equipment
When transporting a load, hazardous situations may occur which can result in
injuries.
When carrying out transport work, always wear protective clothing in
conformity with the currently valid accident prevention regulations (e.g. safety
shoes, protective gloves, etc.).
MX_MC6_V1.9_07.09.15_ENG
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Risk from toppling loads
©KM
When a load is being carried, there is always a risk of it toppling.

Always drive slowly within the work premises and secure the load correctly due
to the risk of the machine toppling!
4-168 Transport/Packaging
w
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Warning!
For air and sea transport, drain nitrogen in pressure accumulator to approx. 10
bar.
w
D
Caution when working above head height
• When performing installation and disassembly work above head height,
use climbing equipment and work platforms that conform to safety
standards.
• Do not use parts of the machine as an aid for climbing.
W
Important
• Machines and accessories must not be uncovered during transport.
• Machines must always be secured on the means of transport even if the
travel distances are only short!
4.2 Requirements regarding personnel operating the machine

Information on training personnel (see section 1.2.3, page 1-54).
4.3 Transport/lifting
W
Important
Only authorized KraussMaffei personnel are permitted to transport the MX
machine.
Move the machine components to the transport position:

• Move clamping unit and injection unit in position for transport locking
(see section 5.7.2, page 5-201),
MX_MC6_V1.9_07.09.15_ENG
• Move back injection plunger and pressure cushion,

• Move the ejector forward.
©KM
4.3.1 Attachment points, lashing points, dimensions and weights
B
m
Only hang machines at these points for transport.
w
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D
Due to their heavy weight, the clamping units are extremely susceptible to
toppling! Machines with a weight > 15,000 kg must be transported only on a
lorry with a load platform height not exceeding 1 m.
w
D
Install transport locks for transport
If the transport locks are missing, this may result in severe damage to the
machine and the transportation personnel may be at risk.
Before transporting the machine, fit the transport locks for the clamping and
injection unit (see section 5.7.2, page 5-201).
D
w
Warning!
If not properly attached, this may result in severe damage to the machine and
transportation personnel may be at risk.
Match lengths of rope.
W
Important
• Before lifting the machine, check that the ropes do not collide with machine
components. If necessary, consult with KraussMaffei Customer Service.
• Observe the centre of gravity of the machine when loading! MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM
Dimensions and weights in the following figures vary according to the

equipment of the machine.
Exact details are available in the shipping documents and on the basis of the
markings.
4.3.1.1 Attachment points/lashing points, clamping unit KM 850 MX to KM 1600 MX, land
transport
6 6 7
6 6
3
5 1 2
5 5
6
7
Fig. 4.1 Attachment points/lashing points, clamping unit KM 850 MX to KM 1600 MX, land transport
1 Length 5 Lashing points (4x)
2 Width 6 Attachment points FP (transport openings)
3 Height 7 Attachment points MP (transport openings)
4 Transport position of movable mold platen
Type Type 1 2 3 4 Weight

Clamping unit Injection unit [mm] [mm] [mm] [mm] [kg]
KM 850 MX SP 4300-SP 8100 5100 2500 2510 2000 33000
MX_MC6_V1.9_07.09.15_ENG
KM 850 MX SP 12000 5100 2500 2650 2000 33000

KM 1000 MX SP 4300-SP 8100 5435 2870 2620 2000 44000
©KM
KM 1000 MX SP 12000–SP 17200 5435 2870 2760 2000 44000

KM 1150 MX SP 4300-SP 8100 6140 3100 2690 2600 56000
KM 1150 MX SP 12000–SP 17200 6140 3100 2830 2600 56000
KM 1300 MX SP 6100-SP 8100 6500 3100 2710 2600 60000
KM 1300 MX SP 12000–SP 17200 6500 3100 2850 2600 60000
KM 1300 MX SP 24500 6500 3100 3130 2600 60000
KM 1600 MX SP 6100-SP 17200 6970 3475 2960 2600 75000
KM 1600 MX SP 24500 6970 3475 3240 2600 75000
KM 1600 MX SP 33000 6970 3475 3450 2600 75000
I
Note
Dimensions and weights vary according to the equipment of the machine.
markings.
W
Important
• Only attach machines at the marked lifting points (transport openings).
• Observe the centre of gravity of the machine when loading!
• If there are sharp edges, place edge protectors between tensioning chain
and machine part or use steel cables.
• Protect corners and edges of the machine with air-cushion film
(see fig. 4.2, page 4-172).
• Place anti-slip mats under the machine.
• Wrap the machine in dust-protection film and, after lashing, cover with
waterproof tarpaulin (see section 4.4.3.2, page 4-188).
MX_MC6_V1.9_07.09.15_ENG
Fig. 4.2 Load the MX clamping unit on a lorry with tarpaulin (example: land transport)
©KM
4.3.1.2 Attachment points/lashing points, clamping unit KM 850 MX to KM 1600 MX, sea
transport
6 6
3
5
5 1 5 2
Fig. 4.3 Attachment points/lashing points, clamping unit KM 850 MX to KM 1600 MX, sea transport
1 Length 4 Transport position of movable mold platen
2 Width 5 Lashing points (4x)
3 Height 6 Attachment points (4x)
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Due to their heavy weight, the clamping units are extremely susceptible to
toppling! Machines with a weight > 15,000 kg must be transported only on a
lorry with a load platform height (distance from ground to loading surface) not
exceeding 1 m.
Permissible trailer type for transport (see section 4.3.2, page 4-180) and
W
Important
MX_MC6_V1.9_07.09.15_ENG
Only attach machines at the marked lifting points.

©KM
The attachment points are indicated by the handling marking "For Lifting".
4.3.1.3 Clamping unit KM 2000 MX to KM 4000 MX
W
Important
The machines KM 2000 MX to KM 4000 MX are dismantled when transported.
If necessary, obtain information from our KM-Service.
4.3.1.4 Attachment points/lashing points injection unit SP 4300 to SP 12000
4, 5
4, 5
3
2 1
4, 5
4, 5
Fig. 4.4 Attachment points/lashing points injection unit SP 4300 to SP 12000

1 Length 4 Attachment points (4x)
3 Height
Type 1 2 3 Weight
MX_MC6_V1.9_07.09.15_ENG
[mm] [mm] [mm] approx. [kg]

SP 4300 6015 2480 2300 11000
©KM
SP 6100 6015 2480 2300 12000

SP 8100 6015 2480 2300 14000
SP 12000 7015 2660 2300 18000
I
Note
markings.
W
Important
Machines with a weight > 15,000 kg must be transported only on a lorry with a
load platform height not exceeding 1 m.
Fig. 4.5 Injection unit is packed in dust-protection film and loaded onto a lorry (land transport on lorry
with tarpaulin)
MX_MC6_V1.9_07.09.15_ENG
©KM
Attachment points/lashing points injection units SP 6100 to SP 12000 with

mounted cabinet
4
4
5
5
3
2 1
4
5
4, 5

1 Length 4 Attachment points (4x)
3 Height 6 Cabinet attachment
MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM

markings.
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Risk of injury
Remove the lifting eyes (4, fig. 4.6) immediately after installation of the
injection unit.
Failure to observe these instructions can lead to serious injury.
MX_MC6_V1.9_07.09.15_ENG
©KM
3
2 1 4

1 Length 3 Height
2 Width 4 Attachment points/lashing points (4x)
Type 1 2 3 Weight
MX_MC6_V1.9_07.09.15_ENG
SP 17200 7770 2800 2400 22000

©KM
SP 24500 8770 2800 2600 25000
I
Note
markings.
W
Important

3
1 2

1 Length 3 Height
2 Width 4 Attachment points/lashing points (4x)
MX_MC6_V1.9_07.09.15_ENG
©KM
Type 1 2 3 Weight
SP 33000 9550 3075 3000 42000
SP 55000 10215 3305 3030 52000
I
Note
markings.
W
Important
4.3.1.7 Injection unit from SP 75000
W
Important
The injection unit from SP 75000 onwards is disassembled for transport. If
necessary, obtain information from our KM-Service.
W
Important
4.3.2 Means of transport

Lorry for supply/follow-up
The machines must be transported with semi-trailers with tarpaulin (semi-flat bed
trailers), which must be in perfect working order and suitable for the machine to
be transported.
Pay particular attention to:
• Regular service of the tractor and trailer.
• Brakes and lights must be fully functional.
• Tyres must have appropriate air pressure and profile.
• Verification of the permissible payload of the trailer.
• Loading sill height max. 1 m.
• Perfect condition of tarpaulin cover.
W
Important
MX_MC6_V1.9_07.09.15_ENG
Due to the danger of tilting, machines must only be transported on trailers with
©KM
a loading sill height (distance ground - loading surface) of max. 1 m.
I
Note
Trailers must comply with German or European standards (DIN/EN) or
standards in the country of destination (provided they are equivalent).
4.3.3 Securing the load

Depending on properties, the machine must be secured against toppling, shifting
and falling off during transport in/on suitable means of transport with a sufficient
load bearing capacity.
The following suitable measures must be taken corresponding to the anticipated
load on the means of transport and the transport route, while observing the
respective national and international guidelines and technical regulations:
• Use of friction-increasing materials (anti-slip mats).
• Load securing points must be freely accessible.
• The load must only be secured directly (diagonal and/or direct lashing)
(1, fig. 4.9). Simple cross lashing is not permitted due to the high centre of
gravity (risk of toppling).
Securing crosswise is only permissible if the arrangement of the load securing
points does not permit direct diagonal securing (2, fig. 4.9).
• Ensure load securing elements are positively fitted: Load is supported by
wooden beams against the front wall (positive locking in direction of travel –
directly or by means of an H-block between load and front wall of trailer)
(see fig. 4.10, page 4-182).
W
Important
• For direct securing of the load, only the lashing points provided by
KraussMaffei should be used.
• Lashing and securing elements (chains, lashing strap, anti-slip mats) must
be sufficiently dimensioned and be in technically perfect condition and
checked for damage.
• If lashing and lifting points are not identical, only use the red-marked lashing
points.
• Place the guard (rubber, wood) between the tensioning chain and the
machine part.
• Only load onto technically faultless lorries.
• When loading the machine onto a lorry, always ensure that the longitudinal
centre of gravity of the machine is positioned on the longitudinal axis of the
lorry.
• The person responsible for the loading operation must be satisfied that the
MX_MC6_V1.9_07.09.15_ENG
machine has been properly loaded and secured prior to handing over the
©KM
shipping documents.
W
Important
As a general rule, only the attachment and lashing points provided by
KraussMaffei should be used for lifting and transporting the machine.
W
Important
• Do not lash over the Injection unit (see fig. 4.11, page 4-183)!
• Lashing down with chains is prohibited!
• When lashing crosswise, ensure that the lashing angle is at least
30 degrees (see fig. 4.10, page 4-182).
1 2
Fig. 4.9 Securing the load to a lorry

1 Diagonal direct securing of the load with chains 2 Direct securing of the load with chains
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 4.10 Clamping unit secure with H-block and lashed crosswise (land transport on lorry)
Fig. 4.11 Incorrect (prohibited) lashing of machine components (injection unit)
4.3.4 Delivery of the machine

• The machine must be checked for completeness and intactness when
delivered.
• Any complaints, such as transport damage, must be recorded immediately on
the transport documents, photographed and the sender must be notified.
• If transport damage was not externally visible upon delivery, the customer
must notify the freight forwarder immediately after discovering damage and
within 7 days at the latest.
• Claims for incorrectly recorded transport damage or damage not reported
within the specified time shall not be entertained
MX_MC6_V1.9_07.09.15_ENG
©KM
4.4 Packaging
4.4.1 Removing packaging

• Use a suitable tool (e.g. screwdriver or knife) to remove the packaging.
• Check the machine for damage in transit!
• If damage to the machine is only discovered after unpacking (hidden transport
damage), please inform KraussMaffei and the responsible forwarding agent
immediately and, where possible, note on the transport documents.
W
Important
In the event of damage:
If damage or rust is determined, stop unpacking immediately.
Leave the machine and accessory parts unaltered. Keep the packaging!
The packaging serves as verification of transport damage during inspection by
an expert.
KraussMaffei shall not assume liability if the packaging has been disposed of.
• Check the shipment for completeness and report any accessories or

components that are missing.
• Dispose of packaging material in an environmentally correct way.
MX_MC6_V1.9_07.09.15_ENG
©KM
4.4.2 Repacking machine
I
Note
Packaging must be suitable for the load and comply with valid national and
international specifications and standards.
Preparatory measures
• Decommissioning (see chapter 13 Taking machine out of service/Placing into
storage/Disposal).
• For air and sea transport, bleed off the nitrogen in the pressure accumulator
to approx. 10 bar (see section 10.16.1, page 10-784).
• Clean the machine (see section 7.3, page 7-299).
• Fasten loose parts (doors etc.).
• Move the machine components to the transport position.
• Fit the transport locks (see section 5.7.2, page 5-201).
• Fit the attachment points and lashing straps (see section 4.3.1, page 4-170).
• Carry out electrostatic protection of control cabinet and control system.
• Take appropriate measures at control components to absorb shocks.
• Remove the control/display panel for transport using the hinges.
• Remove the master switch and EMERGENCY STOP button.
MX_MC6_V1.9_07.09.15_ENG
©KM
4.4.3 Examples of packaging
4.4.3.1 Sea transport

Loading onto lorries, in containers, on flat racks, on Mafi transport systems.
Types of packaging (examples)
With platform (pallet or wooden frame)

Machine component is joined to the platform, wrapped in preservation film and
shrink-wrapped in PE film (polythene).
1 2
Fig. 4.12 Packaging with platform

1 Machine component joined to pallet 2 Machine component joined to wooden frame
Without platform
Machine component is wrapped in preservation film and shrink-wrapped in PE
film.
In container
Machine component is preserved with grease, wrapped in dust-protection film
and stowed in a container.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 4.13 Machine component stowed in a container
In carrier box
Machine component is wrapped in preservation film, shrink-wrapped in PE film
and joined to the bottom of the box. The sides and wooden lid elements are then
joined together.
MX_MC6_V1.9_07.09.15_ENG
1 2
©KM
Fig. 4.14 Packaging with platform

1 Machine component joined to box base 2 Box sealed
4.4.3.2 Surface transport

Machine component is wrapped in dust-protection foil, loaded onto a lorry and
covered with a waterproof tarpaulin.
Fig. 4.15 Clamping unit packed in dust-protection foil and covered with tarpaulin (land transport on lorry
with tarpaulin)
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 4.16 Injection unit wrapped in dust-protection film and lashed onto lorry
4.5 Sea transport of machines with shrinking foil packaging
4.5.1 Transport/load securing
4.5.1.1 Transport on marine vessel

Shipping must take place on container ships below deck.
• The ship must not be older than 15 years.
• Valid IACS classification.
• Port State Control inspections without complaints.
W
Important
Stacking is absolutely prohibited!
4.5.1.2 Containers for marine vessel transport

Flat-rack containers in perfect condition must be used for transporting the
machines.
• Containers must be regularly serviced.
• Containers must have a valid safety certification sign (CSC/ACEP label).
• Verification of the permissible payload of the container.
• Inspect containers prior to loading.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 4.17 Loading flat-rack containers on rolltrailers/Mafi trailers
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When a load is being carried, there is always a risk of it toppling.
• Transport/onward carriage by lorry with machines stowed on flat-rack
containers is not permitted.
• For transport on the company premises, secure equipment appropriately
due to the risk of toppling and drive slowly: max. 5 km/h.
W
Important
• Load the equipment only on terminal chassis in perfect technical condition
(no worn tyres, complete equipment, no missing attachment parts, etc.)!
• Due to top-heaviness, machines with a weight of over 15 tons must only be
transported on jumbo semis or semi flat bed trailers with a rave rail height
(distance from ground to loading surface) of max. 100 cm.
• Exceptions to this are the mold clamping platens and the machine base if
the clamping unit is disassembled for transport.
W
Important
Terminal transport of the flat-rack container:
• The container must only be transported in the container terminal on trailers
(e.g. rolltrailers) that have a corresponding permissible and verified axle
load.
• Permissible trailer type for transport: multi-axle drop trailer.
• Secure or lock the containers on the trailers!
B
m
Only hang machines at these points for transport.
W
MX_MC6_V1.9_07.09.15_ENG
Important
• Lifting with a forklift is prohibited!
©KM
• Only raise the machine with a crane.

• Use only the red-marked attachment points (see section 4.3.1,
page 4-170) provided.
4.5.1.3 Securing the load for flat rack container
W
Important
• Lashing down with lashing straps should be avoided where possible. If
necessary, use edge protection and place a guard (rubber) between the
support and ratchet.
• Lashing down with chains is prohibited!
• Lashing down of injection units is prohibited (see fig. 4.11, page 4-183)!
• For direct securing of the load, only the lashing points provided by
KraussMaffei should be used.
• Lashing and securing elements must be sufficiently dimensioned and be in
technically perfect condition and checked for damage.
• Only attached lashing and securing element at the attachment points
marked "FOR LASHING".
Depending on properties, the machine must be secured against toppling, shifting

and falling off during transport in/on suitable means of transport with a sufficient
load bearing capacity.
The following suitable measures must be taken corresponding to the anticipated
load on the means of transport and the transport route, while observing the
respective national and international guidelines and technical regulations:
• Use of friction-increasing materials (anti-slip mats).
• The load must only be secured directly (diagonal and/or direct lashing)
(1, fig. 4.9).
• Simple cross lashing is not permitted due to the high centre of gravity (risk of
toppling).
• Ensure load securing elements are positively fitted: Load is supported by
wooden beams against the front wall (positive locking in direction of travel –
directly or by means of an H-block between load and front wall of flat rack
container) (see fig. 4.10, page 4-182).
• If lashing and lifting points are not identical, only use the red-marked lashing
points.
MX_MC6_V1.9_07.09.15_ENG
• Place the guard (rubber, wood) between the tensioning chain and the
machine part.
©KM
• Make appropriate repairs to cut (damaged) shrinking film.

• Make a note of all potential damage on the transport documents.
4.5.2 Storage
W
Important
• Stacking is absolutely prohibited!
• Protect the machine from direct sunlight and moisture.
• Do not store outdoors. Where possible, store the machine in the hall.
Provide additional UV-resistant tarpaulins if the machine has to be stored
outdoors!
• Maximum storage period for deliveries with undamaged and unopened
packaging, which are also covered with a UV-resistant tarpaulin: 4 days!
• Avoid damage to the shrinking foil, repair in appropriate manner if
necessary.
• Observe the symbols on the packaging (see section 4.5.3, page 4-192)!
4.5.3 Symbols on the packaging
W
Important
With regard to handling and storage of the packages, the symbols on the
packaging (see tables) and the notes must be observed in all circumstances!
No. Symbol Description Symbol Description
1 Protect against moisture! 4 This side up!

Do not store outdoors!
Do not transport when open!
2 Protect against sunlight! 5 Fragile! Handle with care!

Do not store outdoors!
Do not transport when open!
3 Do not damage the barrier 6 Lifting with a forklift is

layer! prohibited!
MX_MC6_V1.9_07.09.15_ENG
©KM
No. Symbol Description
7 Do not stack!
8 Observe centre of gravity!

Extreme danger of toppling!
9 Attachment points are only for lifting, not for securing load.
Load securing points are only for securing and not for lifting.
10
Only fit load securing elements (straps/chains) on load securing

11 points provided for this purpose!
Lashing down over the machine is prohibited!
Reference to closing or resealing the foil packaging at the

12 attachment points!
If boxes are included in the delivery, the flaps on the box must also be
closed again.
13
Only position ladders in the green-marked areas!
Ladders can only be positioned in the green-marked area to reach the
attachment points for lifting the equipment.
14
Do not enter this area!
MX_MC6_V1.9_07.09.15_ENG
©KM
4.5.4 Additional notes

If you have any questions or issues requiring clarification, please contact the
following person:
KraussMaffei Technologies GmbH

Krauss-Maffei-Str. 2
D-80997 Munich, Germany
Mr Heiko Wachtler
Phone: +49 89 / 8899 - 4471
Fax: +49 89 / 8899 - 15 4471
E-mail: Heiko.Wachtler@kraussmaffei.com
MX_MC6_V1.9_07.09.15_ENG
©KM
5 Installation
This chapter describes procedures and provides information for installing the
injection molding machine. Carry out the procedures in the specified sequence.
5.1 Safety precautions during installation . . . . . . . . . . 196
5.2 Requirements regarding personnel operating

the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.3 Foundation drawing . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.4 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.5 Inspecting scope of delivery . . . . . . . . . . . . . . . . . . 199
5.6 Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . 199
5.7 Installing and aligning the machine . . . . . . . . . . . . 200
5.8 Connection of cooling water . . . . . . . . . . . . . . . . . . 214
5.9 Electrical connection of master switch . . . . . . . . . . 215
5.10 Replenishing hydraulic oil . . . . . . . . . . . . . . . . . . . . 217
5.11 Fill the pressure accumulator with nitrogen . . . . . 221

MX_MC6_V1.9_07.09.15_ENG
©KM
Installation 5-195
5.1 Safety precautions during installation
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Hazard from insufficient load carrying ability of floor
If the floor does not have a sufficient load carrying ability, this will result in
damage to the machine and to the structure. This may also result in personal
injury.
Ensure that the floor load capacity at the installation location meets the
specifications stated in the foundation drawing (see chapter 15 Parts
lists/drawings).
l
d
D
• When installing the machine, there is always a danger of falling loads.
Never stand or walk under raised loads.
• A crane with lifting ropes or lifting tackle of sufficient load carrying capacity
is required for unloading the assemblies. Dimensions and weights
(see chapter 15 Parts lists/drawings).
• The following rules apply to lifting ropes and lifting tackle:
– Arrange them in such a way that the assemblies can be raised and
transported horizontally (not at an angle).
– Attach them only at the points provided for this purpose.
– Arrange them such that injection unit panelling is not pushed in or
damaged.
• If there is no corresponding lifting tackle available for transport in the shop,
the components can be transported on steel rollers. Pay attention to the
composition of the shop floor and any flooring.
r
d
D
Risk of slipping
Oil or hydraulic fluid on the floor causes a risk of slipping.
Use a suitable filling tool (e.g. funnel) for pouring in lubricating oil and hydraulic
medium.
Immediately contain any spilled oil and dispose of it.
MX_MC6_V1.9_07.09.15_ENG
f
d
D
Fire hazard
©KM
Oil and hydraulic fluid present a fire hazard.

Avoid naked flames and objects with hot surfaces when carrying out work on
the hydraulic system.
Use a suitable filling tool (e.g. funnel) for pouring in lubricating oil and hydraulic
medium.
Immediately contain any spilt oil and dispose of it in an environmentally
responsible manner.
5-196 Installation
e
d
D
Risk from electrical system
Before carrying out any connection work, de-energize the mains lead by
removing the fuses and attach a suitable warning notice.
q
d
D
Danger of crushing
To avoid injury through crushing, when installing the machine ensure that the
required clearance behind the injection unit (injection unit in the rear limit
position) of at least 500 mm is observed (see foundation drawing).
w
D
Warning!
Do not remove the transport locks that are marked in red until the assemblies
are in their final position.
Any unsecured movement of the assemblies creates a risk of injury or the
possibility of damage to the assemblies.
b
B
Wear personal protective equipment
When carrying out installation work, hazardous situations that may result in
injury can arise.
When carrying out installation work, always wear protective clothing that
conforms with the currently valid accident prevention regulations (e.g. safety
shoes, protective gloves, etc.).
W
Important
To guarantee safe and clean operation, the machine must be connected to the
compressed air system, or be supplied with compressed air.
MX_MC6_V1.9_07.09.15_ENG
©KM
Installation 5-197
i
t
Basic rules regarding water pollutants
Pay attention to the following basic rules regarding the installation of machines
with water-pollutant substances:
• solid, waterproof flooring,
• no drains in the area of the installation,
• keep a suitable binding agent ready,
• position the system in a collecting trough,
• inspect the shut-off valves and safety devices regularly,
• inspect the system regularly for leaks,
• remove any dripped fluid regularly,
• inform your supervisor regarding defects at the machine,
• inform your employees on how to handle the substances used and any
risks involved,
• inform your employees regarding procedures in the event of an accident,
• be informed regarding the safety data sheets of the substances
Measures to be taken if water pollutants leak out

• Switch off the system immediately.
• Eliminate the cause of the leakage.
• Immediately bind any water pollutants.
• Call the Works Fire Service if necessary.
• Inform the Environmental Protection Department regarding the incident.
• Dispose of packaging material in a proper way.
• Analyse the incident in order to be able to take appropriate measures to
avoid a similar incident in future.
MX_MC6_V1.9_07.09.15_ENG
©KM
5-198 Installation
5.2 Requirements regarding personnel operating the machine

Information on training personnel (see section 1.2.3, page 1-54).
5.3 Foundation drawing

(see chapter 15 Parts lists/drawings)
5.4 Unloading
The injection molding machine is supplied in the following assemblies with
documents and accessories:
• Clamping unit
• Injection unit
• Power and control cabinets
• Operating/display panel
• Screw barrel
• Protective housing
• Wedge shoe machine mounting
• Wedge shoe compensation plates
• Operating instructions and spare parts list (certification for pressure
accumulator, if required)
• Accessories
5.5 Inspecting scope of delivery

• Immediately after the injection molding machine has been delivered, inspect
the entire scope of delivery to ensure that all parts are complete as stated in
the delivery note, and also to determine any damage in transit.
• Damage in transit as well as missing components must be confirmed by the
forwarding agent and reported without delay to KraussMaffei Technologies to
enable appropriate replacements to be obtained and delivered without delay.
• Report any damage in transit without delay to your own insurance company
as we are able to supply replacements only subject to invoice.
5.6 Preparatory measures

MX_MC6_V1.9_07.09.15_ENG
©KM
• Ensure that the following connections and dimensions correspond to the

specifications in the foundation drawing (see chapter 15 Parts lists/drawings):
– Electricity supply
– Cooling water connection
– Compressed air connection (if provided)
– Clearance around the machine.
• Observe the requirements at the installation location for Complete
machine/Electrical equipment (see section 3.3, page 3-151).
Installation 5-19

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Technical Documentation

Operating Instructions for injection molding machine

Original Operating Instructions

Reprinting, even of extracts, and translation require our express approval.

competition without authorization, neither completely nor in part.

1.2.7 Hazards resulting from hydraulic system . . . . . . . . . . . . . . . . . . . . 1-57

1.2.9 Emission of harmful dusts and vapours . . . . . . . . . . . . . . . . . . . . 1-58

1.2.17 Informal safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64

1.5.1 Inspection of the EMERGENCY-STOP buttons and the EMERGENCY-

1.5.10 Check of dynamic clamp safety circuit . . . . . . . . . . . . . . . . . . . . 1-102

3.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131

3.3.1 Ambient conditions for the electrical equipment . . . . . . . . . . . . . . . 3-151

3.4.3.2 Lubrication specification, central lubrication system . . . . . . . . . . . . . . 3-159

4.5.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192

4.5.4 Additional notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194

5.7 Installing and aligning the machine . . . . . . . . . . . . . . . . . . . . . . 5-200

6.3.4.1 Inserting/deleting profile stages . . . . . . . . . . . . . . . . . . . . . . . 6-251

6.3.8 Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-263

6.6.12 Mold nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-285

6.6.13.1 Starting machine cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286

7.13.3 Installation of screw barrel SP 33000 to SP 75000 . . . . . . . . . . . . . . 7-337

7.13.3.2 Supporting the screw barrel SP 33000 to SP 75000 . . . . . . . . . . . . . 7-338

7.17.2 Setting position transducer zero points . . . . . . . . . . . . . . . . . . . . 7-352

8.5.1 Displaying a PDF document . . . . . . . . . . . . . . . . . . . . . . . . . . 8-398

8.5.3 Alarm information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-401

8.6.3 Cycle example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-412

8.8.7.3 Core-step programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-475

8.8.7.5 Symbols for core step programming . . . . . . . . . . . . . . . . . . . . . 8-479

8.9.2.2 Plasticizing configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-499

8.11.5 Water manifolds (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-572

8.13.6 Machine/production status . . . . . . . . . . . . . . . . . . . . . . . . . . 8-626

8.14.1 Machine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-628

8.14.4.6 Production data, mold temperatures . . . . . . . . . . . . . . . . . . . . . . 8-638

8.18.1.1 Creating and renaming categories and notes . . . . . . . . . . . . . . . . . 8-684

8.18.1.3 Exporting note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-688

8.18.4 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-695

10.9.7 Return-flow filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-737

10.9.7.1 Replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-737

10.12 Plasticizing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-748

10.16.1 Drain the nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-784

10.16.3 Installing the pressure accumulator . . . . . . . . . . . . . . . . . . . . . 10-787

11.1.3 Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-791

11.9.1.1 Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811

11.9.1.3 USB memory expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-813

12 Auxiliary devices 12-819

12.4.5 Notes for the programmer of the master computer . . . . . . . . . . . . . 12-867

12.4.6 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-869

12.4.7.3 Wildcard parameter names . . . . . . . . . . . . . . . . . . . . . . . . . . 12-870

12.11.7.2 AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-906

12.11.8.1 AF machine operating buttons . . . . . . . . . . . . . . . . . . . . . . . . 12-908

12.11.9.5 Parameters of the AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-914

12.12.4 Alarms, bar-pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-958

12.12.6 Venting the bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . 12-961

12.14.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-968

13.3 Shutting down the machine . . . . . . . . . . . . . . . . . . . . . . . . . 13-1015

13.4 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1016

0.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

0.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . 27